Rising energy prices, CO₂ costs, and growing sustainability requirements are increasing the pressure on industrial production companies. Many decision-makers are therefore wondering whether modernizing existing drive systems is really worthwhile. The answer is clear: even small measures can have a significant economic impact. This is shown by a recent analysis by the Fraunhofer Institute for Chemical Technology (ICT) and the European Engineering Federation CEMEP.
For many years, Unitechnik has been proving that increasing efficiency does not necessarily require large investments. Often, replacing individual electric motors with efficient IE4 or IE5 models and using modern frequency converters is enough to measurably reduce energy consumption and operating costs. A recent study by Fraunhofer ICT and CEMEP also illustrates the actual energy savings potential of drive modernization. “There is enormous potential lying dormant in many existing plants,” explains Karsten Boldt, Managing Director of Unitechnik Automatisierungs GmbH. “Retrofitting individual drives is often sufficient to achieve savings of 10 to 30 percent with a manageable investment.”
Economic efficiency as a decision-making criterion
Despite demonstrable savings potential, there is often uncertainty about payback periods and investment risks. This is exactly where Unitechnik comes in: reliable analyses show which drives are particularly interesting from an economic point of view even before the project starts. This creates transparency and decision-making certainty for management. Experience shows that most modernizations pay for themselves within a few years. Subsidy programs provide additional support, further reducing investment costs.
One example of an often underestimated savings potential is the recovery of braking energy. Many applications, especially in metallurgy, regularly generate excess energy. Modern frequency converters with energy recovery capabilities feed this energy back into the grid or into storage instead of converting it into heat. “Energy recovery is still underestimated in everyday industrial life,” says Boldt. “Yet it is a direct lever for significantly reducing running costs.”
A holistic approach increases the benefits
In addition to reducing electricity costs, companies also save money after conversion thanks to improved controllability and lower maintenance requirements. Modern drive technology reduces downtime and increases plant availability in the long term. For many companies, this is just as important a factor as energy savings themselves, especially in continuous processes.
Unitechnik supports its customers throughout the entire process—from analysis and planning to commissioning. System-wide optimization is particularly important here: only when all relevant components and processes are considered holistically can savings potential be fully exploited. “Energy efficiency is not a short-term trend, but a strategic success factor,” emphasizes Boldt. “With modern drive technology, economy and ecology go hand in hand.”
