When manufacturers want to improve the energy efficiency of their operations, they often turn to new or developing technologies. With the power of industrial magnets, manufacturing facilities can not only reduce their energy consumption but also their impact on the environment. Using variable frequency drives (VFDs) for their motors, production plants can increase the efficiency of every day machinery. VFDs in motor upgrades can better help manufacturing facilities meet their goal of lowering their energy consumption, including firms that are participating in the Better Buildings program, according to Plant Engineering.

The Better Plants Program was established the U.S. Department of Energy (DOE) as a partnership between the federal government and the commercial and industrial sectors to reduce their energy consumption 20 percent by 2020. Reaching this goal could drastically cut energy usage in the industry sectors overall.

"Overall, Better Plants Partners represent industry sectors that consume about 77 percent of all energy used in the U.S. manufacturing sector," the 2013 DOE report on the progress of the Better Plants Program said. "Currently, the program includes partners that represent close to 15 percent of the U.S. chemicals manufacturing industry's energy consumption and 23 percent of the U.S. transportation equipment manufacturing industry's energy consumption."

How more efficient motors help save energy
To achieve this target, manufacturers have turned to motors made from permanent magnets, including AC motors. VFDs can help improve the performance of AC motors that are found in all sorts of manufacturing facility operations, such as in equipment fans, pumps or other mechanical components. VFDs that incorporate high-efficiency permanent magnetic motor and an optimized bevel gear box can boost motor systems' efficiency level to up to 89 percent, generating as much as 25 percent in energy savings as opposed to regular systems. These permanent magnet motors are usually found in a variety of machinery and gadgets, including portable power tools and packing and material equipment.

The market for energy-efficient AC motors is only growing as more companies look for energy saving solutions to lower operating costs. The global market for these types of motors is projected to have double digit compound annual growth rates from 2013 through 2018, according to a report by Research and Markets. The research firm predicts market growth will reach $44.32 billion by 2018, up from an estimated $23.07 billion in 2012.

Improved motors give operators greater control
​VFDs provide for more control over devices that include an AC motor, enabling plant managers the benefit of customization. VFDs allow the frequency of electrical current to vary and have the motor run at a speed that is appropriate for the workload of the device. This enhanced function from the VFDs cuts energy consumption for equipment that can perform operations when they are partially loaded or ones that do not need large amounts of energy. VFDs also improve efficiency by giving operators a smoother control as well as increase the reliability of the machinery. In addition to saving electricity, better motors can also help conserve water as they can reduce losses associated with irrigation and distribution systems.

To further improve the energy efficiency of their operations, manufacturers benefit from utilizing the DOE's expertise About 13 manufacturers that participate in the Better Buildings Challenge have energy efficiency goals that can be achieved through In-Plant Trainings (INPLTs), which help facilities determine the best way to boost their energy savings.

"Technical expertise gained through the INPLTs help companies overcome a series of critical barriers to adopting energy management practices and technologies, including lack of technical expertise, insufficient senior management buy in for implementing energy-saving projects, and difficulty coordinating actions and best practices across several plants within a company," the report said.