“Our high-efficiency motors, drives, digital solutions and lifecycle services, help industries optimize energy consumption, extend equipment life and reduce carbon footprints.”
The editorial team of Chemical Industry Digest engaged in an insightful conversation on the sidelines of Stakeholder’s Roundtable event hosted recently in New Delhi, with leaders from ABB Motion Services — Oswald Deuchar, Head of Modernisation Services, ABB Motion Service and Amit Gupta, Division President, Motion Services, ABB India. The discussion focused on ABB’s contributions to advancing energy efficiency, driving decarbonisation and fostering innovation in the chemical and process industries. Excerpts from the interactions
are presented below.
Chemical Industry Digest (CID): Could you give us a description of the situation in industry related to motors/drives and how it is changing?
Amit Gupta (AG): Industry-wide, motors consume about 45% of energy, yet only 20–25% of them use variable frequency drives (VFDs). Integrating VFDs significantly improves efficiency. The biggest transformation is happening with the shift from DOL (Direct On-Line) starting methods to Variable Frequency Drives (VFDs). This transition significantly improves
energy efficiency. The industry is transitioning from IE2 motors to IE3, IE4 and IE5 standards. ABB manufactures IE3 motors in India and also provides high-efficiency
synchronous reluctance motors up to IE5. We recently supplied a high-powered synchronous motor achieving 99.13% efficiency, a milestone that was unimaginable
a few years ago. Drives, especially ultralow harmonic (ULH) drives, also play a critical role in improving system efficiency and power quality.
Oswald Deuchar (OD): ABB actively promotes energy efficiency. Our energy efficiency initiatives evaluate customer operations through energy audits to identify areas for improvement. Using advanced technologies, we help industries optimise power usage, which is crucial in a growing economy like India.
CID: How do you deploy your motors and drives in companies with existing infrastructure?
AG: In our motion business, we provide motors, drives and generators along with overarching services. For equipment already installed, we manage the full lifecycle—from installation and commissioning to predictive maintenance, diagnostics and end-of-life replacement. While new products will play a key role, the massive existing installed base in sectors like cement, oil & gas and metals must also be addressed. ABB provides end-to-end solutions—what I’d call appraisals, prescriptions and solutions to help industries optimise their existing systems. We continuously upgrade the system with new technology, retrofitting drives where possible and provide entirely new solutions if needed.
OD: A significant share of inefficiencies stems from aging infrastructure, with much of the equipment in use being 15 – 20 years old. Many high-voltage motors, for instance, were installed without VFDs or soft starters simply because such technologies did not exist at
the time. Through detailed energy appraisals, we identify opportunities where upgrades and retrofits can deliver the greatest benefits—particularly in missioncritical, high-power applications. Our lifecycle services help extend equipment usability until newer technologies become viable. We replace obsolete systems and recycle parts wherever possible, staying true to our sustainability principles. For retrofits, we provide ABB drive solutions while remaining motor-agnostic, servicing third-party motors as well. In parallel, we are embedding digitalisation across equipment and work processes, with strong investments in advanced digital technologies to maximise performance.
CID: How do your motors and drives enable energy efficiency in energy-intensive chemical operations, such as distillation, drying and boilers?
AG: True efficiency emerges when motion solutions are seamlessly integrated with process automation. Motors and drives need to work in harmony with automation systems to optimise operations end-to-end. This synergy becomes especially critical in highpower,
mission-critical equipment, where energy consumption is substantial and precise motor control is essential. In such applications, ABB’s motors and drives deliver the greatest impact—directly improving process efficiency, reliability and uptime.
OD: Automation provides data on process performance, which integrated with our motion solutions, allows us to improve efficiency, particularly in high-energy- consuming and aging infrastructure. By identifying these key areas, we deliver the most impact.
CID: India has set the year 2070 for the decarbonisation goal. What role do your technologies play in accelerating this?
OD: We look at decarbonisation on two levels. First, within ABB itself—we aim to be carbon neutral across all our operations by 2030. This includes the way we manufacture, use energy and manage waste. Second, through our technologies, we enable customers to
reduce their energy use. For example, our high efficiency motors deliver huge savings for energy-intensive industries.
AG: To put this in perspective, motors account for about 45% of electricity consumption and India’s power demand is expected to grow more than threefold by 2050. Studies show that efficiency improvements alone can deliver 37% of the required contribution toward net-zero. That’s why deploying IE4 and IE5 motors, increasing VFD adoption from the current 20% to 60-65% and integrating digital tools like AI and IoT are critical steps.
CID: What policy changes or incentives from the Indian government would most accelerate the adoption of energy-efficient solutions? What are the kind of collaborations needed between government bodies, regulators, customers and you?
AG: Policy support can certainly accelerate the adoption of energy-efficient solutions, but what truly drives change is the right intent supported by collaboration. Indian industries are already setting their own net-zero and sustainability targets and more than 50%
of our production today consists of IE3 and IE4 motors— showing that the shift is well underway. Raising the minimum efficiency standard to IE3 and eventually IE4, would be a strong enabler for India’s sustainability ambitions. Equally vital is collaboration among government bodies, regulators, customers and industry players. By sharing best practices
and creating platforms for collective action, we can balance near-term capital costs with long-term efficiency gains. Energy saved is the cleanest energy and efficiency will remain central to both decarbonisation and competitiveness.
CID: What differentiates your motors and drives from competitors in terms of efficiency?
AG: Our solutions meet and often exceed international standards. For example, the 58 MW motor we delivered surpassed the requested efficiency of 98.4%, achieving 99.13%. Our ultra-low harmonic drives and medium-voltage solutions further improve system-level
efficiency. Continuous R&D, data-driven insights and rigorous appraisals ensure that our products and services remain reliable, consistent and technologically advanced.
OD: ABB invests significantly in R&D to stay at the forefront of innovation. Our R&D centers work closely with customers, industry bodies and academic institutions to anticipate future needs and develop technologies that deliver measurable value. From advanced
motor and drive technologies to digital platforms powered by AI and data analytics, we ensure our solutions address the evolving challenges of efficiency, reliability and sustainability. This continuous innovation allows our customers to access the latest technology, maximise performance and achieve long-term cost savings while also meeting their sustainability goals.
CID: How do you see the demand for your products in India?
AG: The Indian market, which is very important to us is poised for growth. ABB operates across 23 sectors— from industry and building infrastructure to data centers, transportation, robotics and automation. We hold leading positions in most segments. Our strong sales network, supported by over 500 channel partners, enables us to deliver customised solutions backed by R&D and innovation. Our commitment is long-term—
we recently celebrated 75 years of manufacturing and innovation in India and 30 years on the national stock exchange. We have strong R&D facilities here, serving both India and the global market. We are well positioned to deliver customised solutions for Indian industries.
Innovation, sustainability and customer-centric solutions will continue to drive us forward.
OD: Beyond our products, we are committed to sustainability throughout our supply chain, ensuring that our suppliers share the same values. This ripple effect strengthens the overall impact on energy efficiency and decarbonisation.
CID: In summary, how does ABB contribute to energy efficiency and sustainability in India’s chemical and industrial sectors?
AG: Through high-efficiency motors, drives, digital solutions and lifecycle services, we help industries optimise energy consumption, extend equipment life and reduce carbon footprints. ABB’s focus on continuous innovation and process improvement ensures that our customers achieve their efficiency and sustainability targets.
OD: By combining advanced technologies, energy audits, process optimisation and sustainable practices across our operations and supply chain, ABB actively supports India’s energy transition and decarbonisation goals.
