Case Studies

After Sales Sales Call Enquiry Leveraging Advance Stack Testing to Optimize Motor Performance & Cost How precise magnetic characterization enabled a leading motor manufacturer to achieve superior efficiency while reducing material costs through strategic electrical steel selection. Industry Context: Rising Performance Pressures Electric motor manufacturers face mounting challenges:stringent global efficiency standards, escalating energy costs,and intense competitive pressure to optimize productioneconomics. Electrical steel4the core magnetic material4directlygoverns critical performance parameters including core loss,permeability, and ultimately motor efficiency. Traditional core loss testing provides limited insight into thecomplex relationship between magnetic properties andoperational motor behavior. Manufacturers require deepercharacterization to make informed material selection decisionsthat balance cost and performance. The challenge: Beyond Conventional Testing Testing Methodology Gap Conventional core loss measurements insufficient for comprehensive magnetic characterization needed for design optimization. Performance Correlation Required quantifiable insights linking stack magnetic properties – particularly permeability – to actual motor operational metrics. Cost – Performance Balance Needed data-driven procurement guidance to source cost-effective materials without compromising efficiency or quality standards. Solution: Advanced Epstein Frame Testing Ferrites India deployed Epstein Frame testing with integrated BH Loop measurement4an internationally recognized methodology for comprehensive magnetic property characterization. Core Loss Analysis Precise measurement of energy dissipation during magnetization cycles under varying frequencies and flux densities. Permeability Profiling Detailed characterization of material responsiveness to applied magnetic fields across operational ranges. BH Loop Mapping Complete hysteresis behavior documentation revealing magnetic saturation characteristics and remanence properties. Critical Discovery: The Permeability Advantage   Comparative testing of two electrical steel stacks revealed a counterintuitivefinding: the stack exhibiting marginally higher core loss demonstratedsignificantly superior magnetic permeability. This elevated permeabilitysuggested enhanced magnetic flux handling capability4a key driver ofreduced no-load current. Ferrites India’s prediction: Despite slightly higher core losses, the superiorpermeability stack would deliver substantially lower no-load current andimproved overall motor efficiency. Validation & Performance Results Production Implementation Customer incorporated the higher- permeability stack into motor manufacturing lines. Rigorous Testing Comprehensive performance validation conducted under operational load conditions. Confirmed Improvement Prediction validated: significantly reduced no-load current and enhanced efficiency achieved. Measurable Business Impact No-Load Current Reduction Substantially lower idle power consumption confirmed through operational testing, directly improving energy efficiency ratings. Motor Efficiency Gains Enhanced magnetic flux management enabled superior operational performance, meeting stringent efficiency standards. Material Cost Savings Higher-permeability stack offered procurement cost advantages, optimizing the cost-to-performance ratio without quality compromise. Industry Recognition: NRDC Award for Innovation   This breakthrough testing and evaluation methodology earned Ferrites India theprestigious National Research Development Corporation (NRDC) Award for Invention4recognizing significant technological advancement and measurable industry impactin motor manufacturing optimization. Strategic Advantages Achieved Performance Excellence Motors deliver superior efficiency with reduced operational losses, aligning with global sustainability requirements and customer expectations for energy-efficient solutions. Cost Optimization Data-driven material selection enabled procurement savings while maintaining4 and improving4motor quality standards and performance benchmarks. Competitive Differentiation Advanced testing capabilities provide strategic advantage in material evaluation, accelerating R&D cycles and enabling informed design decisions. Key Takeaway: Precision Testing Drives Innovation This collaboration demonstrates how comprehensive magnetic property characterization4beyond conventional core loss measurement4empowers manufacturers to optimize the critical balance between material cost, motor efficiency, and operational performance. The Epstein Frame Tester with BH Loop methodology unlocked insights invisible to standard testing, enabling strategic decisions that delivered measurable improvements in both technical performance and business economics. The Path Forward 01 Adopt Advanced Characterization Move beyond basic core loss to comprehensive magnetic property profiling for complete material understanding. 03 Validate Predictions Implement rigorous testing protocols to confirm material performance predictions in production motors. 02 Leverage Permeability Data Incorporate permeability metrics into material selection criteria alongside traditional core loss measurements. 04 Optimize Procurement Use data-driven insights to balance material costs against performance requirements for maximum value. Advanced stack testing represents a transformative approach to motor design optimization4delivering continuous innovation, enhanced sustainability, and sustained competitive advantage in the demanding electric motor marketplace.

After Sales Sales Call Enquiry How One Motor Manufacturer Cut Costs 20% With Smarter Testing Discover how advanced magnetic testing equipment transformed quality control, slashed process costs, and turned a supplier into a strategic partner. 20% Cost ReductionProcess cost savings achieved 1 Root Cause Defect identified & fixed 100% Vendor ControlEnhanced material quality The Challenge Inconsistent Quality Raw material variations from vendors caused unpredictable subassembly failures in large induction motors. Reliability Crisis Product failures impacted customer trust and warranty costs spiraled as defects emerged in the field. Rising Process Costs Rewinds, scrap, and troubleshooting consumed resources without identifying the true root cause. The Breakthrough Solution During technical discussions about the Epstein Square Tester, the customer discovered it offered advanced hysteresis loop measurements-unlocking deeper diagnostic capabilities for both design and manufacturing teams. 01 Warranty Crisis A year-old motor failed after rewinding despite prior satisfactory field performance 02 Custom Solution Ferrites India modified equipment to enable rapid stack testing and diagnosis 03 Root Cause Found Core defect identified as metallurgical problem related to welding process 04 Process Imprroved Targeted manufacturing improvements prevented similar failures going forward Measurable Impact Defect Resolution Direct stack analysis revealed true failure cause, enabling targeted manufacturing process enhancements 20% Cost Saving Early magnetic inconsistency detection reduced failures, rewinds, wasted time and material costs Vendor Excellence Improved material qualification protocols reduced faulty inputs at source, streamlining quality assurance Strategic Partnership Customer recognized Ferrites India as solution partner, not just equipment supplier Why this Matters Technical Excellence NABL-traceable testing perIEC/ASTM/IS standards ensuresaccuracy and compliance for criticalapplications. Customer-Centric Innovation Customized equipment modificationsand practical support solve real-worldmanufacturing challenges. The Bottom Line: Combining advanced testing capabilities withcollaborative problem-solving, Ferrites India helped improve core quality,reduce costs, and secure greater performance confidence for the largestinduction motors. Ready to Transform Your Motor Quality? See how the Epstein Frame Tester can detect issues early, reduce costs, and strengthen your vendor relationships. Learn More About Testing Solutions