04/03/2026 • What if one equipment upgrade could cut energy use by as much as 75%?
Across multiple industries, manufacturers are already seeing this level of saving by replacing ageing drives with modern, high-efficiency systems such as MOVIGEAR®. In this blog, Stuart Swarbrick explains where these hidden losses occur, how an energy audit reveals them, and why upgrading motors is often the simplest step towards lower costs and lower emissions.
Like many factories around the world, you may be under pressure to reduce your energy consumption, amid volatile electricity prices and tighter carbon reduction regulations.
Phasing out ageing motors and inefficient drives, then upgrading them with higher efficiency systems with Variable Frequency Drives (VFDs) is one of the most effective ways to cut energy use anSimply by controlling motor speed in line with process demand, VFDs can deliver energy savings of up to 50%, as they limit the energy usage to what is required for each task only. This means lower electricity consumption, CO2 emissions, and improved cost efficiency.d operating costs
Simply by controlling motor speed in line with process demand, VFDs can deliver energy savings of up to 50%, as they limit the energy usage to what is required for each task only. This means lower electricity consumption, CO2 emissions, and improved cost efficiency.
Upgrading motors from International Efficiency (IE) IE2 motors to IE3 and IE4 lefficiency classes can further reduceenergy consumption, rlowering your electricity bills while improving your sustainability performance.
In the UK, regulation is also moving in this direction; motors with a rated output from 0.12 kW to below 0.75 kW must meet at least the IE2 efficiency standards. Three-phase motors with a rated output of 0.75kW to 1,000kW must meet the IE3 while certain larger three-phase motors between 75kW and 200kW must now achieve IE4 efficiency.
The biggest energy savings often begin with understanding where power is really being used. That is why an energy audit is one of the most effective first steps you can take as a manufacturer to cut costs and emissions.
At SEW-EURODRIVE, we’ve developed a suite of tools and services to help you get a clear and practical view of your energy performance. Whether you want to understand your CO2 footprint, identify where electricity spend could be reduced, or see how you’re measuring up against current country-specific regulations, we’ll give you a transparent view of the energy savings you could make.
Our consultation starts with the fundamentals. We’ll guide you through modern energy management approaches, explain different motor efficiency classes and outline the legal regulations you need to know. We’ll then conduct a site inspection to collect system data and assess how much energy your processes currently consume.
You will receive a detailed energy report for every system, recommended efficiency components and systems and documented findings from the consultation.
After this, we’ll create a performance review comparing energy use before and after improvements are implemented, giving you clear evidence of the impact.
To help you quickly explore potential savings, our easy-to-use energy savings calculator allows you to compare your existing motor against higher-efficiency alternatives such as an IE3 or IE4 motor.
You simply enter the data of your current standard motor, including type, number of poles, power in kW and load factor, alongside its operating hours and the electricity price you pay per kWh, and we do the rest.
For example, replacing just one 0.75 kW DR2S Series 4-pole motor running for 16 hours a day, five days a week, for most of the year with an IE4 super-premium-efficiency motor, could save around £130 annually. Multiply that across an entire factory and the reduction could quickly reach tens of thousands.
We also support system planning with our Workbench software which allows you to configure drive components and complex automation systems, in an easy drag –and-drop format. The platform checks compatibility of your configured drive system and reports possible combination errors.
This approach recently helped crane and industrial control system specialist, Levate Solutions, select the right motors, gearbox, and other drive components for a bespoke overhead crane project. The result was faster quoting, and the most efficient products for the application, giving Levate the confidence that they were being provided with the best possible solution. Workbench’s user-friendly workspace means it’s easy for you to use yourself, with a function allowing multiple users to collaborate on projects.
See Workbench in action below:
At SEW-EURODRIVE, we’re well versed in bringing more energy efficient solutions to our customers, working with industries from baggage handling through to food and beverage production.
One example is London Gatwick Airport, where more than 1,500 MOVIGEAR® drives were installed as part of a major upgrade to the a baggage handling system. MOVIGEAR® combines motor, gear unit, and corresponding drive electronics in one system, with a compact design that’s tailored for use across materials handling industries.
Since installation, the MOVIGEAR® system has delivered energy savings of 30-50%, and the airport now uses 3,000 efficient drives across its entire 13km baggage handling network. Beyond higher energy efficiency, the drives also have lowered installation time and commissioning costs.
Internationally, similar results are being seen. in Austria, MOVIGEAR® has helped Coca Cola reduce energy consumption by 75%, cutting CO2 emissions by 41,000kg per year, across 40 mechatronic drives.
Closer to home, MOVIGEAR® is also in use at one of Europe’s biggest spirit bottling plants, operated by Diageo, the name behind brands including Baileys, Smirnoff, and Tanqueray. At the Scottish facility, 30 million bottle cases are produced annually, with four bottling halls producing anywhere between four bottles and four hundred bottles per minute.
With the site using approximately 22 GWh/year of electricity, we’re helping Diageo to meet their target of carbon neutrality by 2030. By deploying MOVIGEAR® technology, the site has the potential to reduce energy consumption by up to 50% while maintaining high production throughout the factory. .
Working towards net-zero goals and higher cost efficiencies? Don’t waste your energy with draining drives. Speak to our expert team about booking a FREE energy consultation today.