How ABB is Driving Energy Back to the Grid to Cut Emissions
Data centre operators face mounting pressure to reduce energy consumption as facilities consumed 415 TWh in 2024 – representing 1.5% of global electricity demand.
In response, ABB’s latest white paper identifies data centres as targets for motor and drive efficiency upgrades that could deliver immediate energy savings without requiring new infrastructure.
The company has released research showing that replacing standard electric motors with high-efficiency alternatives paired with variable-speed drives can cut emissions whilst improving productivity. Its approach centres on upgrading the 45% of global electricity consumed by industrial electric motors, of which only 25% currently operate with drives.
“Adopting energy-efficient solutions helps companies cut electricity consumption, minimise waste and extend equipment lifespan, therefore lowering both operational costs and emissions," says Erich Labuda, Division President at ABB Motion Services.
“By doing more with less, energy efficiency preserves resources, reduces dependence on fossil fuels, and cuts operational costs – all while maintaining or even improving productivity, delivering benefits for the planet and for the bottom line.”
ABB audits reveal 43% average energy savings across motor systems
ABB conducted audits between November 2024 and May 2025, screening more than 10,500 motor-driven systems. Among 5,900 systems identified for upgrades, the company recorded average energy savings of 43%, totalling 941,000 MWh.
This figure equals the annual energy consumption of 91,715 US households.
Likewise, ABB’s research supports the COP28 UAE Consensus pledge to double global energy efficiency improvements from 2% to 4% annually by 2030. The company estimates that four efficiency actions across industrial settings could avoid 2.53 gigatonnes of CO₂ annually by 2030, equivalent to emissions from 600 coal-fired power plants.
These actions offer a US$4.1tn gross benefit and a net upside of US$1.23tn after investments.
Variable-speed drives allow motors to adjust speed based on load requirements rather than running at constant full speed. This eliminates energy waste through inefficient throttling, a common problem in facilities that require variable cooling and ventilation loads.
One case study with CERN found that energy audits across 800 motors revealed a 17.4% efficiency improvement opportunity in cooling and ventilation, translating to annual savings of 31 GWh – enough to power more than 18,000 European homes.
Governments demonstrate scale of motor efficiency opportunity
Policy is vital to scaling efficiency, with ABB advocating for ambitious minimum efficiency performance standards (MEPS), tax incentives and smart carbon markets.
In China for instance, ABB has installed more than 11 million high-efficiency motors and drives in the country, saving more than 510bn kWh. This figure equals Shanghai's entire electricity consumption over three years and has avoided 500m tonnes of CO₂ emissions.
Further ABB research indicates 86% of Chinese companies plan further energy efficiency investments, reflecting growing recognition of the financial returns available.
“Energy efficiency is an abundant and cost-effective resource that reduces the need for additional energy supply and paves the way to net zero – that's why the International Energy Agency (IEA) labelled it the ‘first fuel',” Erich explains.
“Yet, only 25% of motors are controlled by variable speed drives (VSDs), which adjust a motor's speed to match actual demand – much like gently pressing the accelerator in a car.”
European copper producer Aurubis replaced 460 motors with IE4 and IE5 models in Bulgaria, many paired with ABB drives. The project cut electricity use by 25 GWh annually and paid for itself in 3.5 years whilst delivering reduced emissions and improved performance.
Digitalisation strategy indicates a strong efficiency foundation
ABB positions digitalisation as fundamental to modern efficiency programmes. Smart sensors and cloud-connected systems provide real-time motor performance data, enabling predictive maintenance and system-wide optimisation.
These capabilities can work to address data centre requirements for maximum uptime and performance monitoring, particularly as facilities are under higher levels of pressure to perform quickly.
For example, Brazilian utility company Saneago deployed ABB Ability smart drives and motors and was able to reduce pumping energy bills by US$700,000 annually and improve uptime.
The solution also enables remote monitoring of energy usage, failure prevention and dynamic operational refinement.
ABB’s Top Industrial Efficiency (TIE) Initiative offers businesses high-performing efficiency options as standard.
In 2025, ABB helped an Indian steel plant achieve motor efficiency of 99.13%, which the company describes as a world record. Over 25 years, this upgrade will save US$5.9m and 61 GWh in electricity.
The company is also advocating for policy support including minimum efficiency performance standards, tax incentives and carbon markets. India’s government for example has made industrial efficiency upgrades eligible for carbon offsets, incentivising businesses to adopt efficiency measures without compromising financial performance.
Erich explains: “Installing higher-efficiency motors can reduce global electricity consumption by up to 10%, equivalent to the amount of electricity used by 300 million households.
“In a time when energy affordability, security and industrial competitiveness are more important than ever, these are opportunities that we cannot afford to ignore.”
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