• Repair and replacement based on lifetime costing.
• Specification of high efficiency motors for all new motors.
• A ‘rewind’ policy (rewound electric motors are less efficient).
• A ‘motor register’ to manage the motors on the site.

Minimising the demand is the first step to managing any service and should be completed before optimizing the supply. It is not economic to optimize the supply based on excessive demand.

Turn it off

Turning motors off is one of the most effective methods of reducing energy usage. This can be done with timers, condition sensors, sequenced operation or by linking downstream equipment to the main processing machine.

Reduce the load

Reducing the load at source can be done by cleaning the systems or lowering pressures. The transmission systems (belt drives or gearboxes) should also be examined, e.g. toothed belts are 2-3% more efficient than standard V-belts.

Select the correct size motor

Operating motors at the maximum efficiency means getting the size right. Many motors are too large for the actual application and using a large motor for a small load increases energy use.

Optimise the supply

Improve motor efficiency
High efficiency motors offer significant energy savings for a small additional cost. Slow the motor down Variable speed drives (VSDs) allow motors to be slowed down to match the demand and offer energy savings and improved process control. VSDs are one of the most important tools available to plastics processors to reduce energy use and costs in pumps and fans. Simply slowing a motor down by 20% with a VSD reduces the energy use by 49%.

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