Boosting Energy Efficiency

At Alpha Drives Ltd, we pride ourselves on delivering innovative solutions that enhance energy efficiency and reduce operational costs for our clients. Recently, we completed an exciting project for a customer focused on optimizing their fan systems. This upgrade not only boosts the efficiency of their fans but also significantly lowers maintenance costs and improves overall uptime.

The Journey from Assessment to Implementation

Our involvement in this project started at the very beginning. The customer identified their fans as high-energy consumers, and after a quick assessment, we concurred. It was evident that upgrading the DOL starters, controls, and motors would result in substantial savings. A comprehensive 12-month system study confirmed our initial findings, paving the way for a more energy-efficient solution.

We decided to implement new damper controls and install a state-of-the-art control panel equipped with SIEMENS SINAMICS G120X VSD and SIMOTICS IE4 Motors.

Key Components of the Upgrade:

  • Siemens Simotics IE4 Efficiency Motors: Available in 75 kW, 132 kW, and 250 kW.
  • Siemens Sinasave Tool: Used to justify and prove the energy savings.

Proving the Savings

For a project of this magnitude, it was crucial to validate the energy savings. We utilized the Siemens SINASAVE tool to demonstrate the potential savings. To ensure accuracy, we conducted a 12-month trial by retrofitting one of the 75 kW fans. The results were impressive, confirming the anticipated savings and leading to the approval of the subsequent steps in the project.

The Benefits of the New System

The original fans, built in 1998, operated at a fixed speed with 100% flow and relied on inefficient damper controls to modulate flow. In contrast, the new system with VSD technology allows for optimal flow control. This upgrade delivers several benefits:

  • Energy Savings: The system operates at the ideal point, significantly reducing energy consumption.
  • Noise Reduction: Improved control leads to quieter operation.
  • Reduced Filter Clogs: Better airflow management minimizes filter blockages.
  • Enhanced Reliability: The new system offers more dependable performance.

Aligning with the European Green Deal

This project aligns with the European Green Deal, where the EU aims to become the first climate-neutral continent by 2050. The revised Energy Efficiency Directive targets a reduction in greenhouse gas emissions by at least 55% compared to 1990 levels by 2030. At Alpha Drives Ltd, we are committed to helping achieve these ambitious goals.

If you’re interested in reducing energy consumption and contributing to the EU’s climate objectives, contact us today at +353 578680800 or email

Together, we can create a more energy-efficient and sustainable future.

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