We introduced our first synchronous reluctance (SynRM) motor in 2011, with the magnet- and rare earth-free technology offering up to IE4 Super‑Premium efficiency. Now as part of ABB’s ‘Engineered to Outrun’ philosophy we are offering IE6 Hyper‑Efficiency SynRM motors as a standard product. They are a great way to help customers get further ahead of rising energy costs and sustainability demands.
The reason for our major focus on motor efficiency is explained by the IEA’s 2025 report that shows industrial electric motor systems account for 60% of global industrial electricity demand. That’s roughly one quarter of worldwide electricity use. The energy demand from these motors rose by about 60% from 2005 to 2023.
Today, more than half of all industrial motors are over 10 years old, with many operating at low efficiency, such as IE1 or IE2. By replacing an older motor with a higher-efficiency model, it’s possible to see a return on investment (ROI) in under two years – even faster when upgrading to the highest efficiency. If the 300-million-plus industrial electric motor-driven systems were replaced with high-efficiency versions, worldwide electricity consumption could be cut by up to 10%.
This is where IE6 Hyper-Efficiency SynRM motors have a key role to play. They enable operators to cut energy costs and emissions even beyond what was possible with IE5 motors.
Inside SynRM motor technology
Externally, a SynRM motor resembles a traditional induction motor. The innovation lies in the rotor, made from laminated iron layers which form a light but solid construction that allows magnetism to flow through it. The rotor aligns itself to the magnetic flux produced by the stator coils, “locking” into position and moving synchronously with it.
SynRM motors combine the performance of permanent magnet (PM) motors with the simplicity and service-friendliness of 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 – improving reliability, motor lifetime, and maintenance needs.
- 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 unplanned downtime and environmental impact.
- Lower total cost of ownership (TCO) – over the typical 20‑year-plus lifetime of a motor, the purchase cost represents only around 2% of its TCO, maintenance about 1%, while electricity accounts for roughly 97%. A motor with superior energy efficiency offers rapid payback through energy savings, and then continues to reduce cost and emissions over its lifetime.
Saving energy costs and avoiding emissions
In a typical 110 kW motor application operating at an average 75% power over 8760 hours, replacing an IE4 SynRM motor and drive with our standard IE6 SynRM package will result in annual savings of €2,560 in energy costs and 4,610 kg of CO₂. Operators who choose IE6 instead of an IE4 package recover that additional upfront investment in around 8 months (at a typical energy cost of €0.2/kWh), making the business case easy to justify.
High performance, same frame size
The IE6 SynRM range is 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. And because they follow traditional kW/frame‑size combinations, they can be used to retrofit older machines without mechanical modifications.
Sustainable by design, not by accident
Sustainability is built into the SynRM portfolio from the ground up. Every IE6 SynRM motor is part of our EcoSolutions™ portfolio, which includes third-party-verified Environmental Product Declarations. The motors are 98% recyclable by weight, and the low‑carbon and recycled copper used cuts emissions by up to 200 kg of CO₂ per 75 kW motor.
SynRM’s magnet‑ and rare earth‑free design makes it a scalable lever for industrial decarbonization. By avoiding rare earth dependence, it helps manufacturers sidestep price volatility and unpredictability with sourcing.
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 CO₂ emissions.
With IE6 Hyper‑Efficiency SynRM motors as a standard offering, we are now making it possible for virtually every motor to lower total energy demand, cut emissions, and increase productivity.
At ABB, we believe that progress is always possible. In a world where to simply ‘run’ is no longer enough, everything we do is ‘Engineered to Outrun’. We help industries run leaner and cleaner by injecting more efficiency and performance into day‑to‑day operations.
To discover more about the ABB’s IE6 SynRM motor range, please visit our web page:
https://www.abb.com/global/en/areas/motion/campaigns/ie6-synchronous-reluctance-expanded-range
