The UK’s cost of living crisis will give businesses, as well as households, much to contend with. One is rising energy costs. According to the UK government, the cost of electricity within the manufacturing industry increased by 72% during the last decade, and 280% over the past 20 years. But, could what at first seem like challenges actually inspire manufacturers to improve their operations?

According to Laura Capper, Head of Manufacturing and Construction at NatWest Group: ‘During the pandemic, manufacturing businesses demonstrated extreme resiliency.’ Capper adds that: ‘While the current inflationary environment creates even more pressures, energy and fuel price rises are a catalyst to consider energy efficient and sustainable alternatives to help manage business costs.’

One apparent challenge that might offer a saving grace for manufacturers are the pending updates to European regulations for Ecodesign (Commission Regulation (EU) 2019/17), set to be introduced by the EU in July 2023. The new legislation could help manufacturing environments become more efficient while offering respite for manufacturers dealing with rising operational costs. Below, we’ll examine how.

New Ecodesign energy requirements  
The pending updates to the European regulations for Ecodesign are the second stage of the legislation changes, following the stricter regulations that came into effect in July 2021, setting out new energy efficiency standards for motors and drives.

From July 2023, this now includes motors that produce between 75 and 200 kW of power, where a minimum International Efficiency Class 4 (IE4) will be standard. IE5 is currently the highest efficiency ranking for motors and is described as ultra-premium efficiency. IE4 refers to super-premium ratings, IE3 motors are noted as having premium efficiency, while IE2 is categorised as high efficiency and IE1 is for standard efficiency.

According to the updated regulations, hazardous area safety motors with a rated output between 0.12 kW and 1,000 kW must now reach the IE2 standard as a minimum. This means that in settings where explosion protection is necessary such as in gas and oil centres or flour mills, motors should now hit higher efficiency ratings. The new rules will also demand that single-phase motors with 0.12 kW power output or above should now have an IE2 level of efficiency as a baseline.

The extra efficiency details from manufacturers, to be included with motors and drives from July 2023 onwards, can help purchasers make better – and more sustainable – motor choices. The details must include efficiency data relating to the different performance settings and show efficiency changes across different loads, speeds and levels of torque.

Although the updated regulations will only apply to motors that are new off the production line, businesses can also upgrade their existing equipment and manufacturing processes to boost their overall energy efficiency.

Reduced maintenance  
For more efficient use of motors, motor and drive manufacturer WEG recommends installing soft starters on machines and motors that run intermittently.

Soft starters limit the load and torque in a power train by increasing the power incrementally, instead of starting the motor suddenly, at full voltage, which creates mechanical stress. A soft starter can reduce the energy in-rush needed to kick-start a motor by 60%.

This has been found to save operators large sums over the course of a decade. First, by reducing the initial energy expenditure needed to get the motor running and, second, by reducing wear and damage to the motor that leads to maintenance costs and likely production stoppages.

Soft starters limit the load and torque in a power train by increasing the power incrementally, instead of starting the motor suddenly, at full voltage – a soft starter can reduce the energy in-rush needed to kick-start a motor by 60%.

Another way in which manufacturers can achieve cost savings is through the use of a variable speed drive (VSD). A VSD is an electronic device with the functionality to calculate and adjust its speed based on the required demands. Put simply, VSDs are able to convert the relative input into a corresponding output.

The advantages of combining VSD drives and motors were demonstrated at a recent installation at Manchester Central Exhibition Centre, in which the ventilation fan drive system for the large venue was replaced with a new and far more efficient system from WEG. When combined with a building management system, the new installation provided savings amounting to a 30% reduction in energy costs and a return on investment of nine months.

Indeed, using a VSD to reduce the power of an electrical motor to 80% of its capacity can reduce its overall energy consumption by up to 50%. The reduction in speed results directly in a reduction of power, and therefore energy.

Long-term efficiency   
Lastly, plant managers can improve motor efficiency by applying Industry 4.0 technologies such as sensors that, when installed at various steps of a line, can support optimal efficiency in each stage of production. Dedicated sensor technologies can monitor a motor’s vibrations, heat and position to give plant managers a better understanding of the asset’s overall health and performance.

For example, if the sensor identifies excessive vibrations in a piece of machinery, then it might be a good idea to check the equipment’s mechanical strength in order to minimise the amount of wasted energy. Industrial sensors can also be used for condition-based monitoring that involves the use of sensors to track the health of equipment, and predict when maintenance is imminently needed. As well as monitoring motors, these sensor technologies can also be used on other assets including pumps, compressors and fans.

When selecting an efficiency-boosting add-on to an existing motor, plant managers must think about how it will impact efficiency in the long run. Fortunately, despite necessitating an initial investment, the energy saving strategies outlined in the new Commission Regulation updates mentioned previously are likely to help manufacturers save money in the long term.

Business owners, especially those that expect the economic crisis to impact their enterprise more than the COVID-19 pandemic, will welcome new energy saving regulations that keep the costs of running a production line as low as possible.