ABB Ltd has introduced the world’s first IE6 Hyper Efficiency motor certified under ATEX and IECEx standards for use in hazardous industrial environments, marking a significant advancement in energy-efficient motor technologies for sectors operating in explosive atmospheres. The newly launched IE6 Increased Safety motor is based on ABB’s synchronous reluctance (SynRM) technology, which operates without magnets or rare earth materials. According to the company, the motor delivers up to 60 percent lower energy losses compared with conventional IE3 induction motors widely used in hazardous Zones 1 and 2.
The technology is designed for industries where combustible gas, vapour, or dust may be present, including oil and gas, chemicals, marine, pharmaceuticals, food and beverage, and process manufacturing industries. ABB stated that the new IE6 SynRM motor has been certified for operation with variable speed drives (VSDs), enabling precise process control and high efficiency across varying speed ranges, including partial-load operating conditions. The motor is expected to support improved operational efficiency in applications such as pumps, compressors, and industrial fans.
The company estimates that replacing a standard IE3 induction motor with the IE6 SynRM motor could generate energy savings of more than €87,000 over a typical 20-year operating life for a 110 kW motor running continuously at 75 percent average load. ABB also stated that the technology could help avoid approximately 157,540 kilograms of carbon dioxide emissions while achieving an estimated payback period of eight months.
Stefan Floeck, President IEC LV Motors at ABB, said increasing global focus on industrial energy efficiency is driving demand for technologies that combine sustainability, operational performance, and cost-effectiveness. He added that the new motor aligns with ABB’s “Engineered to Outrun” strategy focused on helping customers improve productivity while reducing operating expenses and environmental impact.
The new motor portfolio currently covers ratings starting from 110 kW, while IE5 SynRM versions are available for applications up to 90 kW. ABB said the technology also offers additional operational advantages including lower maintenance requirements, improved reliability, and simplified installation compared with traditional hazardous area motor configurations.
In Zone 1 environments, the cooler operating characteristics of SynRM motors may allow users to deploy Increased Safety motor configurations instead of conventional flameproof motors requiring special enclosures. In Zone 2 applications, higher loadability enables greater output from motors of equivalent size, potentially reducing equipment footprint and capital costs.
ABB highlighted that its IE6 and IE5 SynRM technologies form part of one of the industry’s broadest hazardous area low-voltage motor portfolios, which also includes induction motor solutions up to IE4 efficiency levels. ABB Motion, a key business within ABB, develops motors, drives, and automation technologies supporting industries worldwide through energy-efficient and digitally enabled solutions.
ABB operates across more than 100 countries with approximately 110,000 employees globally. The company continues to focus on electrification, automation, digitalisation, and industrial sustainability technologies aimed at supporting energy transition and decarbonisation initiatives worldwide.
