Factories waste vast amounts of electricity every time heavy machinery slows down. This can result in significant energy losses, with each slowdown producing energy that's usually wasted as heat. However, IR Power has developed a plug-and-play system that captures the lost power and slashes energy bills by up to 20%. The company's technology, reducERS electricitity recycling system, works like regenerative braking in an EV, feeding the captured power straight back into the factory grid for immediate reuse.
The system is designed to work with drives and motors from any supplier, rather than being locked into one manufacturer. Multiple machines can be connected into a single energy recovery network across a site. If braking energy exceeds the system's capacity, excess energy is routed to existing waste resistors while the system continues operating. This flexibility makes IR Power's technology an attractive solution for manufacturers looking to reduce their energy consumption and lower their costs.
Traditionally, energy recovery technology required expensive custom engineering, weeks or months of installation, and often modifications to drive systems. These barriers made it difficult for companies to adopt this technology in the past. However, with prices now closer to £100 to £150 per megawatt-hour, and manufacturers facing binding net-zero commitments, the economics look very different.
IR Power's redesign of both the hardware and business model has removed these barriers. The company offers three standardized product sizes meant to cover a range of applications, and installation is designed to take hours, not weeks. This makes it more practical for manufacturers to upgrade their drive systems, which can cost £1 million or more.
The equipment is designed to work with existing machinery, rather than requiring modifications or shutting down production. This means that manufacturers can continue to operate without disruption while still benefiting from the energy savings. The company's rental model also eliminates upfront costs, making it easier for manufacturers to approve internally.
Founder and managing director Richard Bradshaw says the technology has existed for years, but the business model kept it from scaling. He says the company shifted the risk away from customers by eliminating upfront costs and tying payments to proven savings. The equipment is designed to last 15 to 20 years, meaning customers could see more than a decade of net savings after installation.
IR Power plans to begin commercial deployments in 2026, starting with press applications in sectors such as automotive and construction materials manufacturing. The company has intentionally chosen different industries to test the technology under varied operating conditions before expanding further. This will help ensure that the solution is effective in a range of environments.
The potential market includes thousands of machines in the UK across automotive, construction materials, food processing, and other sectors. Target applications are motor-driven machines with frequent start-stop or speed-change cycles, where braking energy is most consistent. International expansion is planned once the model is proven at scale.
By adopting this technology, manufacturers can not only reduce their energy bills but also contribute to a more sustainable future. As industries continue to prioritize environmental responsibility, innovative solutions like IR Power's electricitity recycling system will play an increasingly important role in shaping the future of manufacturing.
The shift towards sustainable manufacturing practices is driving innovation in energy recovery technology, enabling industries to reduce their carbon footprint and lower energy bills.
