Key points
TL;DR: IE6 Motor Technology in Process Industries
IE6 motor technology represents the next leap in electric motor efficiency, offering a 20% energy loss reduction over IE5 models. With motors consuming over half of global electricity, this advancement can dramatically cut operational costs and carbon emissions in energy-intensive sectors like chemical processing, oil and gas and food manufacturing. WEG’s W23 Sync+ Ultra is an early example, designed to deliver performance and reliability while lowering lifecycle costs and reducing downtime through improved thermal management.
As industries around the world strive to balance motor performance with environmental responsibility, IE efficiency ratings have emerged as a critical benchmark for engineers. Electric motors account for more than half of global electricity consumption, making the shift to higher-efficiency motors not just beneficial — but essential. With the anticipated IE6 motor technology efficiency rating set to change the industrial landscape, businesses stand to gain significantly in both cost savings and sustainability.
Marek Lukaszczyk, marketing manager for WEG Europe and the Middle East, shares insights into the latest IE6 motor technology and its potential for the process industries.
Understanding motor efficiency ratings
The International Electrotechnical Commission (IEC) has long served as the global standard-setting body for electric motor efficiency. Through its IEC 60034-30 standard, the IEC defines energy efficiency categories for motors, each corresponding to a specific level of energy loss. The higher the rating, the lower the energy losses and the greater the efficiency.
At the lower end of the scale, IE1 motors are considered standard efficiency. As you move up, IE2 and IE3 represent improved and premium efficiency levels, reducing energy losses by roughly 20% with each step. IE4 motors, categorised as super-premium efficiency, cut losses even further, while IE5 motors, classified as ultra-premium efficiency, reduce losses by an additional 20 per cent. These incremental improvements have made electric motors central to global energy efficiency initiatives.
“The anticipated IE6 classification promises a 20% reduction in energy losses compared to IE5 motors, pushing industrial efficiency to new heights.”
Given that electric motors account for a large share of global energy consumption, they have become a primary target for regulatory improvements. The EU's Regulation 2019/1782 on electric motors and variable speed drives introduced stricter standards in both 2021 and 2023, requiring new motors to meet IE2, IE3 or IE4 efficiency levels depending on their specifications. In fact, the EU became the first region to mandate IE4 efficiency for certain motor categories, setting a precedent for sustainability worldwide.
The rise of IE6 motor technology: pushing boundaries further
But the journey towards even greater efficiency doesn’t stop there. The anticipated IE6 classification promises to push energy efficiency even further, targeting a 20 per cent reduction in energy losses compared to IE5 motors.
While this new standard has yet to be officially codified or mandated by regulation, motors that meet the expected IE6 motor technology benchmarks are already available. A prime example of this leap forward is WEG’s W23 Sync+ Ultra motor.
Unlocking potential in energy-intensive industries
As motor efficiency continues to improve, its impact on energy-intensive industries becomes increasingly evident. Sectors such as chemical manufacturing, oil and gas and food processing are particularly well-positioned to benefit from the cost-saving advantages of IE6 motor technology.
“With energy use accounting for up to 97% of a motor's lifecycle costs, switching to IE6 motors offers industries significant savings and sustainability gains.”
In these industries, where energy consumption accounts for up to 97% of a motor's lifecycle costs, switching to more efficient motors can result in significant savings. Motors are crucial for continuous operations like pumping, compressing and conveying, and higher-efficiency models reduce both operational costs and the environmental footprint.
Moreover, more efficient motors can help extend equipment lifespan by generating less heat, which is essential in industries with harsh operating conditions. For example, the W23 Sync+ line operates across a wide speed range while maintaining torque, eliminating the need for additional cooling systems or ventilation. This reduction in thermal stress helps to minimise maintenance needs and prevent costly downtime.
FAQs: IE6 Motor Technology
What are IE motor efficiency ratings?
They are global efficiency classifications defined by IEC that indicate how much energy a motor consumes with IE6 being the most efficient to date
How much more efficient is IE6 compared to IE5?
IE6 motors are expected to reduce energy losses by an additional 20% over IE5 motors
Is IE6 a regulated standard yet?
No IE6 is not yet mandated but motors meeting its expected benchmarks like WEG’s W23 Sync+ Ultra are already on the market
Why are efficient motors important for industry?
Electric motors account for over 50% of global electricity use so improved efficiency reduces energy costs and carbon emissions
Which industries benefit most from IE6 motors?
Energy-intensive sectors like chemical oil and gas and food processing see major cost and sustainability benefits
How do IE6 motors reduce maintenance needs?
They generate less heat and reduce thermal stress helping to extend equipment life and avoid costly unplanned downtime
What is the lifecycle cost benefit of IE6 motors?
Since energy use makes up to 97% of a motor’s lifecycle cost IE6 motors offer substantial long-term savings
