Australian industry is undergoing a structural efficiency shift. Electrification is accelerating, energy prices are volatile, and emissions targets are tightening. In this context, improving the efficiency of motor-driven systems is one of the fastest, lowest-risk levers available to reduce operating expenditures and carbon.
Electric motors and the systems they drive account for more than half of global electricity use, and around 70% of electricity use in industry, so even small percentage gains translate into large absolute savings across plants and portfolios.
This article explains how ABB’s synchronous reluctance (SynRM) motors, particularly at IE5 ultra premium efficiency, paired with application-tuned ABB variable speed drive can deliver measurable energy, reliability and power quality benefits in Australian manufacturing, mining, food & beverage, and materials processing.
Why are motors the first place to look?
Motors are everywhere on Australian sites: moving air and liquids, compressing gases, turning conveyors and agitators, and powering extruders and mills. Because motors dominate electrical loads, they dominate energy improvement potential. Analyses consistently show that optimising motor systems, choosing higher efficiency motors, right sizing, adding variable speed drives (VSDs), and tuning control, can unlock energy savings at the system level.
The Australian backdrop adds urgency. According to the Australian Bureau of Statistics, national accounts show industry energy end-use increased 4% in 2022–23, even as businesses face pressure to decarbonise and control costs. With electricity’s role in production growing and grid emissions intensity falling, every avoided kilowatt-hour simultaneously lowers bills.
What makes ABB’s SynRM different?
ABB SynRM motors reach IE5 efficiency without permanent magnets. The rotor has no windings or magnets and therefore virtually no rotor copper or magnet losses, running cooler and more efficiently, especially at the partial loads and variable speeds common in industrial duty. When paired with ABB drives, the package provides precise speed control, application macros, and protective routines that are tuned for pumps, fans and compressors. Compared with widely used IE3 induction motors, ABB documents up to 40% lower energy losses for its IE5 SynRM range.
From a sustainability and supply chain perspective, magnet-free IE5 SynRM also avoids rare earths in the rotor, reducing exposure to commodity risks while simplifying end-of-life pathways—all without sacrificing performance.
Since the rotor has no windings, SynRM motors have lower bearing temperatures, which results in a longer lifetime and extended service intervals. Every 15°C drop in bearing temperature roughly doubles the grease lifetime while maintaining the same reliability. Typically, SynRM motors run 10–15°C cooler than conventional motors.
ABB Drives: turning motor potential into system results
A high-efficiency motor delivers its full value only when the system around it is controlled intelligently. ABB variable speed drives provide that control layer:
- Variable speed control matches output to actual process demand (flow, pressure, temperature, or torque), avoiding throttling and bypass losses. This reduces wasted energy from throttling or bypass losses.
- Application-specific functions reduce mechanical stress and improve equipment lifetime.
- Minimising harmonics with built-in mitigation, including ultra-low harmonic options, avoiding the need for costly external filters.
These features translate into lower energy bills, improved reliability, and easier compliance with power quality requirements.
How motors & variable speed drives impact Australian industries
Mining & minerals.
Haulage aside, processing plants are dominated by pumps, fans, thickeners, crushers and conveyors. Variable ore characteristics drive variable load, an ideal match for SynRM and drives. Energy improvements drop straight to the bottom line in a sector with large continuous loads and remote network constraints.
Food & beverage.
Chilled water and refrigeration, CIP (Clean-in-Place) systems, air handling, and packaging lines all benefit from variable speed and high efficiency motors. Partial-load performance matters here, because plants rarely run every asset at full capacity year-round.
Building materials & chemicals.
Kilns, mills, extruders and mixers see long duty cycles. Drives mitigate mechanical stress while enabling torque rich low speed control; IE5 motors curb thermal losses and extend bearing and lubricant life.
Water & wastewater within industrial estates.
Many industrial precincts operate their own pumping and treatment systems. SynRM motors and drives can reduce energy consumption and harmonic distortion, easing local network interactions and community impact.
A practical roadmap for Australian industries
- Focus on large energy consumers that run long hours - process fans and pumps, chilled water, air compressors, materials handling. Use metering or drive logs to identify assets with sustained throttling or frequent stop-start cycles, both signals that variable speed will pay back.
- Specify ABB IE5 motors with ABB variable speed drives, not one without the other. Motor efficiency classes (IE3→IE4→IE5) reduce inherent losses, while drives match output to demand.
- Optimise control loops. Drives unlock their value when the process signal is accurate: pressure, flow, temperature, dissolved oxygen, torque, etc. Set sensible deadbands and minimum speeds to keep equipment efficient.
- Manage harmonics on sensitive supplies. For networks with sensitive loads or constrained feeders, consider ABB ultra-low harmonic drives. They help stay within utility limits without sacrificing energy savings.
- Monitor and improve continuously. Track energy intensity by line or process area. Treat year one results as a baseline for continuous improvement and maintenance planning.
Why ABB SynRM and ABB Drives from IPD
At IPD, we combine these elements, helping customers build robust business cases and select the right ABB motor drive packages for their applications.
With motors accounting for most industrial electricity use, upgrading to ABB IE5 SynRM motors with ABB variable speed drives delivers measurable energy and emissions reductions, improved reliability and power quality, and better process control.
For plant managers and engineers, it’s a practical, actionable way to cut costs without compromising output or safety.
For more information contact IPD to discuss your needs on 1300 556 601 or visit our website ipd.com.au