ABB Expands IE6 SynRM Motors for High-Power Industrial Drives

Industrial process industries, utilities, and large-scale manufacturing continue to focus on motor efficiency as a direct lever for reducing operating costs and emissions. ABB has expanded its range of IE6 Hyper-Efficiency synchronous reluctance (SynRM) motors, making the technology available in larger frame sizes and higher power ratings suited to mainstream industrial use.

The IE6 SynRM motors are now offered across a power range from 110 to 450 kW in frame sizes 280 and 315, with speeds up to 3600 rpm. This expansion builds on ABB’s earlier introduction of magnet-free IE6 SynRM technology and positions IE6 efficiency as a standard option rather than a niche solution.




Efficiency gains beyond IE5 motor technology
Upgrading from IE4 induction motors to IE5 SynRM motors is already known to deliver substantial efficiency improvements. ABB reports that moving further to IE6 SynRM technology increases these benefits significantly. Over a typical 20-year operating life, the step from IE5 to IE6 delivers an additional 76 percent improvement in combined energy savings, return on investment, and CO₂ reduction¹, with a reported payback period of around eight months.

For a representative 110 kW application, lifetime savings are calculated at €51,200 and 92,200 kg of CO₂³, illustrating the impact of efficiency gains in continuously operated equipment such as pumps, fans, and compressors.




Magnet-free design and sustainability considerations
The SynRM motors use a magnet-free rotor design, eliminating the need for rare earth materials and supporting end-of-life recyclability. ABB states that the motors are 98 percent recyclable and are part of its EcoSolutions™ portfolio, with Environmental Product Declarations verified according to ISO 14025 Type III standards. This provides transparency on environmental impact and circularity for procurement and lifecycle assessments.

The motors are designed with the same mounting dimensions as standard induction motors, enabling direct replacement without mechanical redesign. When paired with variable speed drives, they are intended to deliver further efficiency gains through optimized speed and torque control.




Energy efficiency in a broader industrial context
ABB links the expanded availability of IE6 motors to broader industrial decarbonization efforts. The International Energy Agency’s World Energy Outlook 2025 highlights energy efficiency as one of the most cost-effective measures for improving industrial productivity and reducing emissions². By extending IE6 efficiency into higher power ranges, ABB targets applications where motors account for a significant share of total energy consumption.

¹Substituting an IE4 induction motor with an IE5 SynRM could avoid annual CO₂ emissions of 2,610 kg. With ABB’s IE6 SynRM as the standard option, this increases to 4,610 kg – a 76 percent improvement.
²IEA (2025), World Energy Outlook 2025, IEA, Paris, License: CC BY 4.0 (report); CC BY NC SA 4.0 (Annex A).
³Calculation based on a 110 kW motor application with a 8760 hour running time at 75 percent power and an assumed energy cost of €0.2 per kWh.

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