ROCKWOOL Reduces Energy Consumption with Ultra-Premium Efficiency Motors

Application Area: Industrial Process Optimization / Motor Systems
Industry Sector: Building Materials / Sustainable Manufacturing

ROCKWOOL, a major supplier of stone wool insulation for residential, industrial, and marine sectors, is focused on reducing energy loss and noise pollution through its products. To align its internal operations with its 2050 net-zero goals, the company's production facility in Roermond, Netherlands, sought to address technical inefficiencies in its motor-driven systems. The primary operational challenge involved identifying which legacy motors (IE1 and IE2 classes) across the plant were underperforming.

The goal was to pinpoint energy-saving opportunities that met a corporate seven-year payback criteria while adhering to local energy saving regulations. ROCKWOOL selected ABB for this project due to their long-standing partnership under an ABB Motion OneCare service agreement. The deployment involved a comprehensive energy appraisal of 42 motors, leading to a turnkey upgrade of the most inefficient units without disrupting the plant's maintenance schedule.

Data-Driven Energy Appraisal
Through a fleet-level appraisal, ABB analyzed 42 electric motors and their corresponding frequency converters. The study evaluated motor sizing, efficiency classes, and control strategies under real operating conditions. By leveraging the data captured by installed frequency converters—including vibration, current, flux, and operating hours—ABB utilized advanced analytics to identify targeted upgrades.

While initial assumptions suggested limited room for improvement, the data-driven approach revealed that eleven motors qualified for immediate replacement. "Where little gain was expected, the analysis showed that as many as eleven motors qualified for replacement," says Wouter Stams, Project Engineer at ROCKWOOL. "Without the data from the frequency converters and ABB’s energy appraisal, we could not have substantiated that conclusion."



Implementation of High-Efficiency SynRM Technology
Based on the appraisal's findings, eleven IE1/IE2 motors were replaced with IE4 and IE5 Ultra-Premium efficiency Synchronous Reluctance (SynRM) units. These motors were paired with ABB ACS880 variable speed drives to optimize performance. The SynRM units are designed without magnets or rare earth materials, supporting circularity and responsible innovation.

The technical benefits of this upgrade include:

Operational Support and Circularity
The project was completed within one year of investment approval. Beyond the installation, the partnership focused on the lifecycle of the hardware. Under the ABB Motion OneCare agreement, the frequency converters utilize real-time remote monitoring and ABB Ability™ Predictive Intelligence to maintain efficiency and support preventive maintenance.

The transition also prioritized circularity through the responsible dismantling of legacy equipment. ROCKWOOL received a destruction certificate confirming that 98 percent of the materials from the old motors were recovered through specialized recycling processes. ABB further assisted with investment planning and securing local subsidies, such as the Energy Investment Allowance (EIA), to ensure the project’s financial viability.

Edited by Romila DSilva, Induportals Editor, with AI assistance.