Fuelled by the introduction of more stringent IE efficiency classes, manufacturers are chasing headline efficiency figures which could only have been dreamed of just 10 years ago. There’s no denying that this is a positive thing for industry, but is motor efficiency just the tip of the iceberg?

Geared motors have offered solutions to a number of challenges in a variety of industrial sectors for many years, and now, with ever increasing pressure to improve efficiency and reduce costs, more innovative and flexible solutions are being created.

Electric motors are estimated to consume 70% of all the energy used in industry. Bearing this in mind, it’s no small wonder that there is an ongoing process of legislation requiring new technologies to adhere to ever higher standards of efficiency.

Improving the energy efficiency ratings of electric motors is a worldwide goal, but exemptions in the regulations mean that for applications in potentially explosive atmospheres there is no obligation to implement the latest technology.

When it comes to bulk materials handling, geared motors are used to power a wide variety of handling equipment from pumps to conveyors and bucket elevators. Different materials and operating conditions mean that each application can pose an individual challenge requiring expertise and a wide range of solutions in order to guarantee both product flexibility and universal reliability, real-world gains in efficiency however can only be achieved through an integrated design approach.

Video - The official opening of the new Bauer production facility at the company headquarters in Esslingen.

From January 1st 2015 the latest efficiency regulations for electric motors come into force in Europe whereby any new installation using a motor between 7.5 kW and 375 kW must use either an IE3 rated motor or an IE2 motor installed with a variable frequency drive (VFD). Aimed at improving the overall efficiency of the installed equipment across Europe, the regulation is supported by a new standard, EN50598, which benchmarks the efficiency ratings of electric motor drives.

Efficiency, reliability and total cost of ownership are all terms that are at the forefront of engineering considerations, however looking at items of equipment on an individual basis may not deliver the maximum benefits. By looking at the wider picture and combining the best technology from individual areas it is possible to achieve much more significant savings and efficiencies.