In today’s industrial landscape, energy efficiency has become a key priority for manufacturers worldwide. WEG, in partnership with BDC - its long-standing distributor based in Blois - has modernised a PVC mixer originally installed in 1998. This upgrade was executed for a prominent French manufacturer specializing in durable PVC, PP, and PE pipes, fittings, and accessories, with the goal of improving energy efficiency and reducing maintenance costs.
The project involved replacing an outdated and energy-consuming DC motor with a highly efficient WEG synchronous PM motor. The primary objective was to achieve significant energy savings, and the results have been impressive. Regular performance measurements indicate an average energy savings of 30%, with some measurements showing savings as high as 35%. This reduction in energy consumption highlights the effectiveness of the new motor + VFD in optimizing operational efficiency.
The decision to choose synchronous technology was driven by its ability to meet the demanding performance requirements of the installation while minimizing maintenance needs. The compact size of the motor was also a key factor in selecting this solution, as it was ideally suited to the specific constraints of the installation site. This customized approach underscores WEG's expertise in delivering tailored solutions to meet the unique needs of its customers.
A key component of this project was the custom engineering solution provided by WEG’s dedicated team. The Engineering department carried out in-depth strength analyses and designed a specific adapter flange in terms of its size and the mechanical strength required for this type of assembly. This flange guarantees the structural integrity and safety of the suspended motor, despite its reduced size to allow the motor to pass through the customer's machine. Demonstrating WEG's commitment to providing customised, high-precision solutions, even in complex applications.
The project also involved the integration of a complete control system. WEG’s AFW11-C drive solution, assembled on electric panel with built-in CFW11 drive to power the newly installed motor. Its compactness has made it possible to retain the DC electrical panel, thus offering the end user the option of reverting to this power supply mode if necessary
The project timeline followed a meticulous and structured decision-making process. Beginning in 2022, the decision to replace the motor was finalized in early 2023. In May 2023, WEG France collaborated closely with BDC and the end-user customer to finalize the design, and a firm order was placed in early 2024. The customized machine was delivered in October 2024, and the motor was commissioned in December 2024 during a planned technical shutdown. This timely execution was made possible through seamless communication and collaboration between WEG, BDC, and the customer.
BDC: A Trusted Long-Term Partner
BDC, with 25 years of expertise, has been a trusted partner of WEG. Their role in the success of this project was pivotal, providing precise and efficient solutions and overcoming technical challenges, such as limited space for motor installation and strict energy efficiency requirements. The mutual trust between WEG and BDC has been a cornerstone of their successful collaboration, which has paved the way for future projects, including the potential integration of WEG’s new generation of hybrid motors, such as the WEG W23 Sync+.
