IE6 SynRM motors set the benchmark for industrial energy efficiency
23/02/2026 ABB Limited (Zurich)
In 2011, ABB pioneered magnet and rare earth-free synchronous reluctance (SynRM) motor technology offering up to IE4 Super-Premium efficiency. The portfolio has now evolved to include the anticipated IE6 Hyper-Efficiency class, available as standard for safe area applications. Daniel Eberli, Global Business Line Manager, ABB IEC LV Motors, explains how SynRM technology is Engineered to Outrun - with the new IE6 range setting a new benchmark for motor efficiency, cutting energy use and emissions while keeping reliability and uptime firmly in focus.
Industrial electric motor systems account for about 60% of global industrial electricity demand and roughly one quarter of all electricity use worldwide, according to the International Energy Agency’s Energy Efficiency 2025 report. The energy demand from these motors rose by about 60% from 2005 to 2023, driven largely by growth in emerging economies.
At the same time, more than half of all industrial motors in operation today are over 10 years old, and many fall into lower efficiency classes such as IE1 or IE2. Many operators don’t realize that replacing older motors with higher-efficiency models typically delivers a payback in under two years in a range of industrial applications – even faster when moving to the highest possible efficiency classes. And, if the 300-million-plus industrial electric motor-driven systems operating today were replaced with high-efficiency versions, worldwide electricity consumption could be cut by up to 10%.
This is why ABB is bringing IE6 Hyper-Efficiency SynRM motor technology to a wide range of industrial applications such as pumps, fans and compressors – allowing operators to cut energy costs and emissions beyond what was previously possible with IE5 motors. In parallel, ABB has extended its IE5 SynRM safe area range down to small frame sizes, so more applications can benefit from Ultra-Premium efficiency on a consistent platform.
Inside SynRM motor technology
Externally, a SynRM motor looks very similar to a traditional induction motor. Even the stator (the non-moving part) inside is traditional. The innovation lies in the rotor. It is made from laminated iron layers which form a light but solid construction that allows magnetism to flow through it. The shape is precisely designed to guide magnetic reluctance within the rotor. As a result, the rotor will align itself to the magnetic flux produced by the stator coils, essentially “locking” into position. This enables it to move at exactly the same speed as the magnetic flux — synchronously, hence the name synchronous reluctance motor.
SynRM motors combine the performance of permanent magnet (PM) motors with the simplicity and service-friendliness of induction motors. And because there are no magnetic forces in the rotor, maintenance is as straightforward as with induction motors.
The practical benefits of IE6 SynRM motors
- Higher reliability and longer lifetime
A SynRM motor has up to 30°C lower winding temperatures and up to 15°C lower bearing temperatures than an induction motor. This improves reliability, prolongs motor lifetime and reduces the need for maintenance. Lower bearing temperatures are a particularly important factor in reducing life-cycle costs because bearing failures cause about 70% of unplanned motor outages.
- Easier service and maintenance
With no magnets or rotor windings, IE6 SynRM motors are simpler to service. Reduced heat and wear extend maintenance intervals, while cutting the unplanned downtime and environmental impact from frequent replacements.
- Lower total cost of ownership (TCO)
Lower energy usage and reduced maintenance directly lower TCO. Over the typical 20-year-plus lifetime of a motor, the initial purchase cost represents only around 2% of its TCO, maintenance about 1%, while the electricity to run it accounts for roughly 97%. A motor with superior energy efficiency will quickly pay for itself through energy savings, and then continue to deliver cost and emissions reductions over its lifetime.
For example, in a typical 110 kW motor application operating at an average 75% power over 8760 hours, replacing an IE4 SynRM motor and drive with the now standard IE6 SynRM package will result in annual savings of €2,560 in energy costs and 4,610 kg of CO-. And for those already considering a move from IE4 to IE5, taking the extra step to IE6 can deliver up to 76% higher energy and CO- savings compared with the IE5 solution.
High performance, same frame size
In 2024, ABB was the first manufacturer to offer the anticipated IE6 efficiency level in a SynRM design for specialized applications. The next step is this broader IE6 SynRM range, making efficient motor technology available as a standard solution across a wide power range of 110 to 450 kW, in large frame sizes 280 and 315 for safe area applications.
The IE6 SynRM motors bring new possibilities for compressor OEMs and other high-speed applications operating at 3000/3600 rpm, with ABB’s offering in this speed range now expanded to cover 110 kW up to 450 kW as standard. And because the new motors follow traditional kW/frame-size combinations, they can directly replace older, less efficient machines without changes to the mechanical setup.
Scaling SynRM where it matters most
ABB has also extended its SynRM offering beyond the new IE6 range in large frame sizes (280, 315). As of September 2025, three smaller IE5 SynRM frame sizes (90, 100 and 112) expand the portfolio to cover 0.75 kW to 450 kW, with other ratings available on request.
Historically, the smallest IE5 SynRM motor available was 5.5 kW (frame size 132). However, smaller motors are often deployed in high volumes and in continuous-duty or space-constrained environments, where thermal performance, precise control, and high efficiency under partial load are critical.
Customers have made it clear that a consistent technology platform across power classes makes it easier to manage fleets that use multiple motor sizes. In response, ABB has focused on bringing IE5 SynRM motor technology to smaller machines that can sometimes be overlooked in efficiency upgrades.
As well as introducing smaller options, ABB’s IE5 SynRM liquid-cooled motors from 37 to 710 kW extend these efficiency and reliability benefits to high-power, space-constrained and noise-sensitive applications. They still enable straightforward drop-in replacement of less efficient machines.
Sustainable by design, not by accident
Sustainability is built into the SynRM portfolio from the ground up. Every IE5 and IE6 SynRM motor is part of ABB’s EcoSolutions™ portfolio, which includes third-party-verified Environmental Product Declarations to support compliance and reporting. The motors are 98% recyclable by weight, and the copper used in their production is covered through low-carbon and recycled copper sourcing. As a result, embedded emissions are cut by up to 200 kg of CO- per 75 kW motor.
On top of that, SynRM’s magnet- and rare earth-free design makes the technology a scalable lever for industrial decarbonization. By avoiding dependence on rare earth supply chains, it helps manufacturers sidestep price volatility and unpredictability with sourcing. High performance without rare earth materials allows customers to reduce electricity use, cut CO- emissions, and improve productivity without sacrificing performance.
The expansion to our SynRM portfolio means we can now help customers hit efficiency and emissions goals across their entire motor fleet. Critically, it opens up the possibility for increased energy efficiency, reduced emissions and higher returns on investment for customers previously unable to benefit from SynRM technology.
Major efficiency gains at Aurubis with ABB IE5 SynRM technology
A large-scale modernization at Aurubis’ copper production site in Pirdop, Bulgaria — Europe’s largest producer of copper — is proof of the measurable impact of ABB’s SynRM technology. The plant upgraded several critical process motors, including pumps, fans and conveyors, to 460 ABB IE4 Process Performance and IE5 SynRM models controlled by ACS880 variable-speed drives.
The retrofit delivered annual electricity savings of roughly 25-GWh, cutting 12,000-tons of CO- each year. Payback was achieved in about three and a half-years, supported by reduced heat, vibration and bearing wear, which extended uptime and service intervals. And by consolidating motor supply from 42 vendors to just one, Aurubis was able to simplify spare-parts management and reduced inventory costs.
Cement plant produces concrete evidence for energy savings
The cement industry currently represents about 7% of carbon dioxide (CO2) emissions globally and is the third-largest industrial energy consumer, that’s according to the International Energy Agency (IEA). That means the potential for energy savings, and avoidance of the associated CO2 emissions, is also huge. Therefore, we have explored the benefits of switching to our IE6 Hyper-Efficiency SynRM motors at a large European cement plant producing up to 3 million tonnes per annum (Mtpa).
There can be up to 1,200 low voltage (LV) motors working hard behind the scenes in roles such as conveyors, pumps, fans and dosing. Most of them could be direct-on-line (DOL) models with an IE2 energy efficiency rating.
If the plant’s motors were upgraded to IE6 SynRM and variable speed drive (VSD) packages, then our simulations show that the annual energy usage would be slashed from 93.30 to 67.65 gigawatt-hours (GWh). That 27.5% saving would save the plant more than Euro 2 million in energy costs per year (based on an energy price of Euro 0.084 per kilowatt-hour (kWh)). If we anticipate a lifetime of 20 years, then the savings could be Euro 40 million. Of course, the higher the local energy price then the higher the potential savings.
ABB’s SynRM portfolio is leading the next efficiency leap
In a world where industrial motors account for such a large share of global electricity use, boosting motor efficiency is one of the most immediate and impactful ways to cut energy use and CO- emissions.
With our extended IE5 SynRM safe area range and the introduction of IE6 Hyper-Efficiency SynRM motors as a standard offering, ABB now makes it possible for virtually every motor to play a part in lowering total energy demand, cutting emissions and increasing productivity.
At ABB, we believe that progress is always possible – that something can always run more efficiently and productively than it did the day before. In a world where to simply ‘run’ is no longer enough, at ABB, everything we do is ‘Engineered to Outrun’. We help industries run leaner and cleaner by plugging more efficiency and performance into their day-to-day operations. And as protecting our planet becomes everyone’s responsibility, the only way industry can truly pull its weight is by making this kind of progress the norm rather than the exception.
To discover more about the ABB’s IE6 SynRM motor range, please visit:
https://www.abb.com/global/en/areas/motion/campaigns/ie6-synchronous-reluctance-expanded-range
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ABB Limited (Zurich)
ABB Industrial Automation
Affolternstrasse 44
Zurich
8050
Switzerland
Tel: +65 (0)6773 5857
Web: https://www.abb.com
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