At Kernova, we are witnessing how the electrification of industrial machinery is not just a trend, but a necessity to remain competitive in the manufacturing sector. We are writing this article today because we firmly believe that industry is at a turning point. Companies that adopt electrification will reduce their operating costs and contribute to a more sustainable future.
In this article, we will look at how the transition to electromechanical systems is helping different industries optimise their efficiency, reduce maintenance and extend the service life of their machines. We will also explore practical cases and analyse the tangible advantages that companies in different sectors are already experiencing.
Personally, I am interested in this subject because I believe industrial electrification is an opportunity to transform the sector, allowing companies to be more competitive and sustainable in the long term. Reducing costs is important, but moving towards a more efficient and sustainable model is the future.
How industrial electrification reduces operating costs
The shift to electric systems eliminates a large part of the expenses associated with the maintenance and consumption of hydraulic machines. Electromechanical systems, such as the Smart Eco-Motion Kit, need no hydraulic oil and have no leaks, which considerably reduces unplanned stoppages and repair costs. These systems work with electric actuators that convert energy into linear or rotary motion, eliminating the need for hydraulic pumps or valves. Electric power drives the motors directly, transmitting force more efficiently and precisely. In addition, because they do not depend on complex circuits or multiple components subject to wear, these systems have a longer service life. The simplicity of their design allows continuous operation with less technical intervention, translating into higher machine availability and an improvement in the plant’s overall productivity.
What impact does energy efficiency have on costs?
One of the main strengths of electrification is energy saving. Electromechanical machines reach an efficiency of over 80%, while hydraulic systems stay at around 60%. This difference can translate into an energy consumption reduction of over 35%, depending on the application and the sector.
In addition, the compact design and the elimination of auxiliary systems allow an installation that takes up to 30% less space, which optimises resources even further.
What maintenance do electromechanical systems require?
Scheduled predictive maintenance is another advantage that reduces operating costs. Electric machines have fewer wear elements and do not depend on pressurised fluids, which significantly reduces unexpected breakdowns. The only maintenance needed is lubrication of certain components.
This contrasts with hydraulic systems, where oil leaks, pumps and valves require frequent and costly checks. In addition, electromechanical systems maintain constant performance even in adverse weather conditions, whether they operate at 20ºC or -10ºC.
How do noise and safety affect operating costs?
Benefits of electrification in terms of safety and noise:
Another area where electrification offers advantages is noise reduction. Electromechanical machines operate below 70dB, improving working conditions and reducing the risks associated with prolonged exposure to high noise levels.
From a safety point of view, electric systems do not use pressure vessels, eliminating the risk of explosions or serious accidents. This improves staff safety and reduces the costs associated with insurance policies and compliance with occupational safety regulations.
Practical cases of electrification in the industrial sector
Companies in the recycling, agribusiness and injection moulding sectors are already adopting solutions such as the Smart Eco-Motion Kit.
Recycling presses, for example, have shown a significant improvement in energy efficiency and reduced downtime.
- In the agribusiness sector, food processing lines have seen significant increases in production speed, reducing material losses and improving the uniformity of the final product.
- Injection moulding machines, for their part, achieve faster and more precise production cycles, making it possible to manufacture parts with a smaller margin of error and optimising the use of raw material. This transition to electrified systems reduces environmental impact and also improves companies’ competitiveness by lowering their operating costs and increasing their production capacity.
- Industrial machinery for building maintenance (BMU) also benefits from this change, achieving greater precision and control in operations. Electrified systems allow greater adaptability to different types of structures and maintenance tasks, improving the reach and load capacity of the equipment.
- In addition, electromechanical operation reduces vibrations and ensures smoother movements, which minimises component wear and extends the service life of the machinery. This evolution allows more efficient planning of building maintenance, optimising working times and reducing risks for operators.
Electrification as a profitable investment
Feasibility and return-on-investment analysis is necessary for companies that are evaluating electrifying their machinery. Solutions such as KRN-Series make it possible to maximise returns, offering a technology that is adaptable and ready to integrate the latest innovations.
The redesign and integration process is fast and ensures that the transformed machines meet the most demanding standards. During this phase, a thorough study of the existing machinery is carried out to identify areas for improvement and adapt the electrical components.
Finite Element (FEM) calculation tools are used to simulate operating conditions and validate each stage of the project, from material selection to the final configuration of the actuators and control systems.
This predictive analysis makes it possible to optimise the design, ensuring that the machines operate efficiently and safely, comply with international regulations and last longer.
Frequently asked questions
How much does it cost to electrify industrial machinery? The cost of electrification varies depending on the type of machinery, its size and the adaptations required. Generally, the return on investment is reached quickly thanks to energy savings and the reduction in maintenance costs over time.
How does electrification affect the service life of machinery? The service life of electrified machinery is usually longer because there are fewer components subject to wear and no hydraulic fluids, which minimises breakdowns and prolongs efficient operation.
Can old machinery be electrified? Yes, most hydraulic machines can be adapted with electromechanical systems through redesign and integration processes, which makes it possible to modernise them and improve their performance without having to buy new equipment.
What type of machinery can be electrified?
From hydraulic presses to injection moulding machines and recycling equipment, almost any heavy machinery can benefit from the electrification process.
What is the estimated energy saving?
Depending on the sector and the application, the energy saving can exceed 35% compared with hydraulic systems.
What level of maintenance does an electrified machine require?
Maintenance is mainly limited to lubricating certain components, which drastically reduces costs and unplanned stoppages.
