Powering the Future: How Energy-Efficient Industrial Automation Parts Drive Sustainable Manufacturing

As manufacturing industries face rising energy costs, stringent sustainability regulations, and pressure to maintain productivity, energy-efficient industrial automation components have become essential. At Industrial Automation Co., we pride ourselves on offering parts from top-tier brands such as Allen-Bradley, Siemens, Mitsubishi, Yaskawa, Schneider Electric, LS Electric, and Hengst—helping businesses meet their operational goals while reducing their environmental impact.

In this blog, we’ll explore why energy-efficient industrial automation parts are key to modern manufacturing, provide concrete examples of specific products, detail how these components enhance operational efficiency, and give a real-world case study showing how these components drive sustainable success.

Why Energy-Efficient Automation Parts Are Essential

Energy efficiency is more than just a trend—it’s a business imperative. Companies across industries are realizing that cutting energy consumption does more than lower utility bills; it also improves sustainability, reduces maintenance costs, and enhances productivity. With tightening environmental regulations and corporate sustainability targets, optimizing energy usage is crucial.

The right automation parts—servo drives, VFDs, robotics, and HMIs—help manufacturers achieve these goals by offering:

• Reduced Energy Waste: Components like servo motors and variable frequency drives (VFDs) adjust their energy draw based on demand, minimizing unnecessary consumption.
• Enhanced Precision and Control: Automation parts ensure that machines operate optimally, reducing energy spikes, minimizing wear, and improving overall system efficiency.
• Sustainability Compliance: Implementing energy-efficient components helps companies comply with global standards like the ISO 14001 for environmental management.

Key Industrial Automation Parts for Energy Efficiency

Here’s how specific automation parts offered by Industrial Automation Co. deliver significant energy savings, including real-world product examples:

1. Allen-Bradley PowerFlex Variable Frequency Drives (VFDs)

Allen-Bradley PowerFlex VFDs, part of Rockwell Automation, are designed to control motor speed by adjusting frequency and voltage. By reducing motor speed during off-peak times, VFDs lower energy consumption without compromising performance.

• Product Example: PowerFlex 755 offers high-performance motor control with built-in safety features, ideal for manufacturing applications where energy savings and safety are top priorities.
• Benefits: These VFDs can help reduce motor energy consumption by up to 50%, extending the life of your equipment while drastically lowering energy costs.

2. Siemens SINAMICS Drives and SIMOTICS Servo Motors

Siemens’ SINAMICS drives and SIMOTICS servo motors are known for their precise control and energy-efficient operation. These motors adjust their power draw based on real-time demand, making them ideal for high-precision applications.

• Product Example: The SINAMICS S120 drive, paired with SIMOTICS motors, provides dynamic and flexible motion control, ideal for high-speed packaging and robotics applications.
• Benefits: Siemens drives offer energy savings through precise load matching, reducing consumption during periods of low demand.

3. Yaskawa Sigma-7 Servo Motors

Yaskawa’s Sigma-7 servo motors offer superior speed and torque control, providing real-time adjustments to power draw for maximum efficiency. These motors are ideal for applications like material handling, packaging, and robotics.

• Product Example: The Sigma-7 Servo System features advanced tuning for minimal vibration and high response, optimizing energy use and improving overall machine performance.
• Benefits: Yaskawa’s servo systems contribute to energy savings while ensuring high precision, reducing wear and extending the lifespan of your equipment.

4. Schneider Electric Altivar Process Drives

Schneider Electric’s Altivar Process Drives are designed for industrial applications with built-in energy monitoring and optimization features. They help reduce energy consumption across a variety of processes by providing real-time insights and control.

• Product Example: Altivar 600 Process Drive is specifically designed for water treatment plants, mining, and other energy-intensive operations. It optimizes performance while reducing energy use.
• Benefits: Schneider’s focus on energy management ensures up to 30% energy savings by tailoring motor control to process needs.

5. Human-Machine Interfaces (HMIs)

While HMIs themselves don’t consume significant energy, they play a crucial role in managing and optimizing energy use across entire systems. HMIs provide operators with real-time data to make informed decisions about energy usage.

• Product Example: Allen-Bradley PanelView Plus offers enhanced data visualization tools to track energy consumption and identify areas of inefficiency.
• Benefits: By giving operators real-time access to energy usage data, HMIs help reduce energy waste across the production line.

Case Study: Norgren’s Energy Efficiency Upgrades in Colorado

A shining example of how energy-efficient parts can revolutionize manufacturing comes from Norgren, a global leader in motion and fluid control technologies. Norgren’s Colorado headquarters faced inefficiencies with their compressed air systems, which ran at full power even during low-demand periods.

To address this, Norgren:

• Installed Allen-Bradley PowerFlex Variable Frequency Drives (VFDs): The VFDs allowed Norgren to regulate the speed of their compressors, adjusting power usage based on real-time demand. This reduced excessive energy consumption during off-peak hours.
• Fixed System Leaks: By repairing leaks in the air piping system, they reduced wasted energy that had been contributing to higher operational costs.

Results:

• Energy Savings: Norgren reduced its energy consumption by 421,904 kWh annually, saving $39,000 in energy costs per year.
• Rebates: Through a partnership with Xcel Energy, Norgren received a $32,658 rebate, further enhancing the ROI of the upgrades. The payback period for the improvements was just 4.5 years.
• Operational Efficiency: The upgrades, particularly the VFDs, enabled Norgren to dynamically control their energy usage, cutting power costs and reducing wear on equipment.

This case demonstrates how the right automation parts—specifically VFDs—can significantly impact energy efficiency, operational costs, and sustainability.

The Long-Term ROI of Energy-Efficient Automation Parts

While the upfront costs of energy-efficient components may be a consideration for some manufacturers, the ROI is compelling. Beyond immediate energy savings, these parts:

• Extend Equipment Lifespan: By reducing wear on machinery through optimized energy use, components such as VFDs and servo drives help lower maintenance costs and extend the life of critical assets.
• Meet Sustainability Goals: For companies aiming to reduce their carbon footprint, energy-efficient parts are a direct way to achieve sustainability goals, improving both corporate reputation and compliance with regulations.
• Improve Productivity: As seen in the Norgren case, energy-efficient automation systems can also lead to more reliable and precise operations, improving throughput and reducing downtime.

Take Action: Enhance Your Efficiency with Industrial Automation Co.

Investing in energy-efficient automation parts is more than just good business—it’s essential for the future of manufacturing. Whether you’re aiming to reduce energy costs, enhance sustainability, or improve system performance, Industrial Automation Co.Allen-Bradley, Siemens, Mitsubishi, Yaskawa, Schneider Electric, and Hengst.

Contact us today to learn more about how energy-efficient automation parts can power your business for the future.