ROCKWOOL, a leading supplier of fire-resilient stone wool insulation, is advancing its sustainability agenda at its Roermond production facility in the Netherlands. By partnering with ABB for a comprehensive fleet-level energy appraisal, the company identified significant opportunities to reduce its energy use and environmental footprint, leading to the adoption of high-efficiency motors.
Based on fast wins and long-term optimization solutions pinpointed through the appraisal, ABB recommended replacing eleven IE1/IE2 motors with IE4 and IE5 Ultra-Premium efficiency SynRM units. This upgrade delivers estimated annual energy savings of 738 MWh - enough to power around 200 European households - and avoids 142 tonnes of CO₂ emissions.1
ROCKWOOL’s stone wool insulation solutions span residential and industrial buildings, marine and offshore sectors, and even greenhouse horticulture. By addressing modern living’s challenges from energy loss to noise pollution and water management, the company delivers comfort, safety, and efficiency. Sustainability is the foundation that underpins ROCKWOOL’s business model and value chain, with a commitment to net-zero CO₂ emissions by 2050. Seizing energy saving opportunities and upgrading to ultra-premium efficient SynRM motors - free from magnets and rare earth materials - is a key milestone on this path.
Harnessing data for immediate and lasting results
Through the energy appraisal at ROCKWOOL Roermond, ABB assessed 42 electric motors across the plant, covering efficiency classes from IE1 to IE2, and their frequency converters. The analysis examined motor sizing, efficiency levels (IE) and control strategies, giving a clear view of how motor‑driven systems were performing under real operating conditions. A key advantage was the installed frequency converters’ ability to continuously capture operational data, such as energy use, vibration, current, flux and operating hours. This supports condition based and predictive maintenance and, when processed through ABB’s advanced analytics and domain expertise, helps identify targeted upgrades with measurable energy and CO₂ savings.
The results challenged initial assumption: “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.”
Based on this, ABB recommended upgrading eleven motors to IE4 and IE5 Ultra-Premium SynRM units, paired with ABB ACS880 variable speed drives. The solution meets ROCKWOOL’s seven-year payback criteria. Further reinforcing the company’s commitment to responsible innovation, the selected SynRM motors are part of the ABB EcoSolutions™ portfolio, with third-party verified Environmental Product Declarations (ISO 14025 Type III).
“We delivered a turnkey solution to minimize the burden on ROCKWOOL, and aligned carefully with their maintenance schedule to avoid disruptions,” notes August Zaal, Account Manager at ABB Motion Services. “The project was completed within a year of investment approval.”
Partnership in practice: expertise and execution
Wouter Stams explains: “We have been working with ABB for years, as they understand our processes and focus on what we value most. They are the ones who have supplied all our high-power electric drives, under an ABB Motion OneCare service agreement. When we needed an inventory of motors due for replacement based on energy consumption, involving ABB was a logical step. The energy appraisal proved highly effective.”
Within the ABB Motion OneCare agreement in place with ROCKWOOL, safe and efficient operation of motors and drives is covered. In addition, the frequency converters are equipped with real-time remote monitoring. Operational data is analyzed via ABB Ability™ Predictive Intelligence to support performance optimization, energy efficiency and preventive maintenance.
“This inventory is linked to the legal requirements and research obligation for energy savings, but our main driver is group policy,” adds Kirstin Goossens, Environmental Manager at ROCKWOOL. “We apply an eight-year payback period instead of the legally mandated five, allowing more impactful solutions to reduce our environmental footprint.”
Beyond efficiency: circularity
Another important aspect of the project was the responsible dismantling and disposal of the legacy motors. ROCKWOOL received an official destruction certificate, confirming that the disposal and processing are carried out in compliance with environmental standards and local regulations. Notably, motors are composed of highly recyclable materials, with no less than 98 percent recoverable through specialized processes.
“ABB supported us on every front, not only selecting the motors but also with the investment planning, local subsidy opportunities such as the Energy Investment Allowance (EIA), and the necessary preparations before implementation. ABB’s strong commitment to help industries do more with less makes them an invaluable partner,” concludes Wouter Stams.
[1] Source: Electricity price statistics - Statistics Explained - Eurostat & Greenhouse gas emission intensity of electricity generation in Europe | Indicators | European Environment Agency (EEA)
