www.hpmag.co.uk HYDRAULICS & PNEUMATICS June 2026 41 areas in particular worth examining on any site: Variable speed drives. Adding a VSD to an application that currently runs at fixed speed can deliver substantial savings, often with a rapid return on investment. Pumps and fans running at full speed but with throttled output are prime candidates. Slowing the motor to match actual demand rather than restricting its output mechanically can significantly reduce energy consumption— and, in some whole-system evaluations, payback periods can be measured in months. Right-sizing. One of the most common sources of energy waste identified by field engineers is oversized motors. A motor running well below its rated load operates inefficiently. If a motor has been oversized as a precaution, there may be an opportunity to replace it with a correctly sized unit and realise immediate ongoing savings. The wider drivetrain. Gearboxes, couplings, belts, and bearings all introduce losses. Unlike motors, these components have seen far less regulatory attention and technological improvement over the decades. A thorough system audit may well reveal that the gearbox or pump is a greater source of inefficiency than the motor driving it. Measure properly before you act Any assessment of system efficiency is only as good as the data behind it. This is another area where shortcuts are common and costly. Taking a brief energy reading during a single operating cycle and declaring the system efficient or inefficient is unreliable. Systems often run under varying loads, with different products, at different temperatures and speeds throughout the working week. Extended monitoring that captures performance data across representative operating cycles, ideally over several weeks, provides a much more accurate picture of where energy is actually consumed and where improvements will have the greatest impact. Condition monitoring technology has advanced significantly and is increasingly accessible for industrial operators of all sizes. A practical framework for equipment owners The takeaway for equipment owners is not to ignore motor efficiency standards as compliance remains a legal requirement, and the regulations have been broadly effective in raising the baseline. The takeaway is to treat motor replacement as an opportunity for a broader conversation. When a motor comes up for replacement, whether through end of life, failure, or planned refurbishment, ask the following questions before simply ordering a like-for-like replacement: Is this motor the right size for the actual load it drives, or has it been oversized? Is the driven equipment (pump, fan, compressor, conveyor) operating at the efficiency for which it was designed? Is there a VSD already installed, or could one be justified on energy-saving grounds alone? When were the gearbox, coupling, and transmission components last assessed? Who in the organisation is looking at the lifetime energy cost of this asset, not just the purchase price? Has enough operating data been captured to understand how this system actually performs under real-world conditions? These questions cost nothing to ask. The answers could be worth considerably more than the most efficient motor on the market. For further information please visit: www.theaemt.com Looking to source fluid power systems and equipment? www.hap-guide.com Interactive Buyers’ Guide website
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