PowerFlex drives cut energy use by up to 30% amid rising costs

Electrical switching & drive systems & components

Third Quarter 2026 Electrical switching & drive systems & components

With energy costs continuing to rise, the integration of PowerFlex 755TS drives into industrial systems is enabling significant efficiency gains, cost savings and improved uptime across Africa’s most demanding operations, according to Referro Systems, a leader in industrial automation solutions and Rockwell Automation’s local distribution partner. “Operators have reported energy reductions of between 10 and 30%, directly bolstering profitability in tariff-hiked markets,” says Referro Systems managing director, Adrian van Wyk.

He explains that this is a benefit to the market, particularly in light of Eskom’s recent tarrif hike of 8,76%. “Deployed in the daily operations of the continent’s industrial sectors, any inefficiencies can have a significant contribution to cumulative financial losses.”

The PowerFlex 755TS with TotalFORCE technology arms industrial operations with adaptive control, predictive maintenance and energy-saving features as standard. The addition of TotalFORCE to the PowerFlex range of variable frequency drives brings a simplified and consistent user experience, allowing users to leverage a common drive for multiple applications, simplifying support and reducing burdens on staff.

“Traditional mechanical tweaks alone fall short in the fast environments we operate in, and true advancement demands intelligent motor control and real-time data analytics. This is precisely where the PowerFlex 755TS VFD technology changes operations,” says Van Wyk.

Loads seldom run at steady states, they surge and dip unpredictably. Van Wyk notes that the 755TS automatically adjusts motor performance based on load changes, with its adaptive control algorithms dynamically fine-tuning motor speed and torque. “This ensures smooth and consistent material flow even under fluctuating demand,” he says.

The drive’s onboard predictive analytics monitor vibrations, temperatures and performance metrics in real time, flagging early warnings such as bearing wear and mechanical resonance. Maintenance teams receive actionable alerts through integrated dashboards, allowing interventions before failures escalate. For African operators, this translates to downtime reductions of up to 50%, freeing resources for growth rather than crisis management. The PowerFlex 755TS Economiser mode optimises output voltage to match real-time loads, reducing waste, while its Energy Pause mode shifts the drive to a low-power standby during idle periods, and compatibility with premium efficiency motors amplifies savings.

The drive also offers seamless integration with operating systems. “Working with platforms like FactoryTalk for centralised oversight, we have seen how commissioning is straightforward. Our team of engineering specialists, who have in-depth knowledge of all the industrial automation and control solutions, can also provide further support where needed,” says Van Wyk.

“The PowerFlex 755TS is no ordinary VFD, it’s a next-generation powerhouse engineered to boost productivity, whether you’re hauling ore in the Democratic Republic of the Congo or aggregates in South Africa,” concludes Van Wyk.

For more information contact Referro Systems, +27 12 349 1297, [email protected], [email protected]

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Electrical switching & drive systems & components

PowerFlex drives cut energy use by up to 30% amid rising costs

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