Grace under pressure: how the right motor technology transforms compressor performance
25/06/2026 ABB Limited (Drives & Motors)
Compressors never stop working — and neither does the pressure on the engineers and OEMs responsible for keeping them running. In sectors like HVAC, data centers, food & beverage, pharmaceuticals, and marine operations, a compressor that underperforms doesn't just cost energy: it costs uptime, product quality, and competitive edge. Daniel Eberli, Global Business Line Manager at ABB, explains how the latest generation of IEC LV motors redefines what compressor performance looks like — leaner, cleaner, and built for the long run.
The hidden cost sitting inside every compressor
Most operators focus on the compressor itself. But the motor driving it often tells a more important story. Around 70% of the total cost of running a compressor system comes from the energy consumed by its motor. Across a typical 20-year service life, electricity accounts for roughly 97% of total cost of ownership (TCO) — the purchase price is merely 2%. That single insight changes the conversation. It means that choosing the right motor technology isn't a procurement decision — it's a strategic one.
The importance of energy efficiency is reinforced by the fact that compressed air systems are significant energy consumers. For example, compressed air systems (CAS) account for around 10% of all industrial electricity consumption. That totals around 8.8 terawatt–hours (TWh) annually, resulting in CO2 emissions of 3,100 kilotons (kt) per year.
Beyond energy, the stakes are equally high for reliability. Many industrial compressed air systems lose as much as 20%-30% of the air they produce to leaks, often driven by heat and vibration-induced material degradation. Poor torque stability accelerates wear, particularly in oil-free compressors with tight mechanical tolerances. The ability therefore to extend service intervals and reduce unplanned downtime is no longer a nice-to-have—it's essential.
Multiple motor technologies, one mission: engineered solutions for every compressor challenge
There is no universal answer to compressor motor selection. The right choice depends on the specific demands of the application — whether that means pushing the boundaries of energy efficiency, delivering high torque in a tight footprint, or eliminating mechanical transmission losses altogether. ABB's "Engineered to Outrun" philosophy has shaped a portfolio of motor technologies, each designed to address a distinct set of compressor challenges:
- Maximum energy savings with unmatched reliability
When efficiency and sustainability are the primary objectives, ABB's synchronous reluctance (SynRM) motors set the benchmark. Magnet-free and rare earth-free by design, they deliver the performance of permanent magnet motors with the simplicity of induction motors. Now available as standard at the anticipated IE6 Hyper-Efficiency class, they run up to 30°C cooler at the windings and 15°C cooler at the bearings than equivalent induction motors. Cooler bearings mean longer life. That makes this thermal advantage critical since bearing failures in regular motors account for approximately 70% of their unplanned outages.
The financial case is compelling: Selecting an IE6 SynRM motor and VSD drive package, instead of an IE4 induction motor, on a 110 kW application at 75% average load delivers €51,200 in energy savings and avoids 92,200 kg of CO? over 20 years — with payback in approximately eight months.
- Compact design for maximum output – with liquid cooling a major advantage
When space constraints or thermal management challenge drive design decisions, ABB's IP23 open drip proof (ODP) motors deliver a distinct benefit. Their open-ventilated construction achieves higher power density than conventional enclosed designs — more output per frame size and meaningfully reduced footprint. The inherent airflow architecture simplifies system design and reduces ancillary energy consumption, making this the smart engineering choice for indoor industrial environments.
Where space is at a particular premium, liquid-cooled motors offer a compelling answer. This is available for ABB's IE5 SynRM liquid-cooled motor — the world's first of its kind. By circulating a liquid coolant through channels or jackets around the motor, the heat generated during operation is effectively absorbed and removed. The higher thermal conductivity of the liquid compared to air allows for more efficient heat transfer and reduced footprint. Liquid cooled motors have no cooling fans, which means less noise, and leaves ambient airflow undisturbed. This is a critical advantage in food and beverage environments such as chocolate production, or in pharma and plastics manufacturing where airborne contamination must be controlled.
Whatever the actual motor technology, the compact footprint offers designers the flexibility to deliver the same power from a smaller footprint or more power from the existing footprint.
- Direct torque without mechanical losses
When mechanical transmission losses must be eliminated, low voltage permanent magnet (PM) motors remove the need for gearboxes by delivering high torque at low speeds directly. With fewer moving parts, installation is simpler, engineering hours are reduced, and spare part inventories shrink. Driven by variable speed drives (VSDs), they provide precise speed control without feedback devices — making them a strong fit for demanding environments in mining, water treatment, and pulp and paper.
- Flexibility to match any compressor application
For OEMs designing across varied load profiles and operating environments, ABB's process performance induction motors deliver proven adaptability. Available across frame sizes 71 to 500 and efficiency classes IE2 to IE5 with outputs up to 1,300 kW, their modular construction can be configured precisely to match the specific compressor design — whether running direct-on-line (DOL) or paired with a VSD for precise speed and torque control. This flexibility ensures reliability without compromise on efficiency or long-term durability.
Engineered to outrun in practice: measurable impact across three industries
The business case for advanced motor technology in compressors is already playing out across industries worldwide.
At Campbell's Shepparton plant in Australia, a 72 kW ABB SynRM and VSD package installed on a refrigeration compressor saves €9,000 per year in energy costs while avoiding 131 tonnes of CO? annually. The results were compelling enough that the site upgraded three additional refrigeration compressors with the same technology.
In Switzerland, Coop's large-scale bakery relies on four refrigeration systems delivering 8 MW of combined cooling capacity — equivalent to roughly 40,000 domestic refrigerators. ABB IE4 motors and VSDs power a system using natural ammonia refrigerant, aligning operational performance with the company's CO? reduction commitments.
In Germany, the Ammertal-Schönbuchgruppe (ASG) waterworks in Ammerbuch-Poltringen uses ABB IE5 SynRM motors and VSD packages to drive eluate compressors in a clean water softening system — an application where energy management and reliability are equally non-negotiable.
Built for any compressor operation
Selecting the right motor is only part of the equation. Deploying it confidently — across regions, regulatory environments, and supply chains — is where ABB's global reach makes the difference. With over 140 years of expertise and a worldwide network of sales and support, ABB ensures fully compliant, locally relevant solutions with reliable on-time delivery, wherever the compressor operations run.
For compressor OEMs and industrial operators, the message is straightforward: the motor inside your compressor is your greatest lever for productivity and sustainability. The right choice is worth getting right.
Learn more: ABB IEC LV Motors for Compressors
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ABB Limited (Drives & Motors)
Daresbury Park
Daresbury
Warrington
Cheshire
WA4 4BT
Tel: 01925 741111
Email: contact@gb.abb.com
Web: https://global.abb/group/en
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