Modernize Your Industrial Mixer:
Why VFD Conversions Are a Smart Investment

If you’re running your industrial disperser or mixer on an old mechanical variable-speed pulley system, you are missing out on performance and savings. Variable frequency drive or VFD conversions are a proven, cost-effective way to bring new life to your equipment — giving you quieter operation, better control, and lower maintenance costs. Whether you’re focused on productivity, efficiency, or sustainability, switching to a VFD system delivers across the board.

Mechanical Drives vs. VFDs — What’s the Difference?

Traditional variable-speed pulley drives are mechanically complex systems. They rely on physical adjustment of belts and pulleys to change speed, which introduces wear over time and limits the precision of control. They’re also loud and are expensive to repair or replace.

VFDs, by contrast, use electronic control to adjust motor speed. This digital approach allows operators to fine-tune blade tip speeds with pinpoint accuracy. That means less downtime, more efficient mixing, and a longer lifespan for your equipment.

vfd conversions for industrial mixer — Variable Speed Drive: Assists in Controlling Speed/Torque of 3-Phase Induction Motors

The Value of Modernization

Retrofitting your existing industrial mixer with a VFD isn’t just an upgrade — it’s an investment in the long-term performance of your machine. Here are a few benefits:

Lower operating and maintenance costs: With fewer moving parts and less mechanical friction, VFDs reduce the risk of breakdowns and the need for routine repairs.
Quieter operation: Say goodbye to the loud, grinding sounds of aging pulley systems.
Greater control: Adjust motor speeds on command to match your process needs — improving consistency and quality.
Energy savings: When full power isn’t needed, VFDs ramp down motor speed, cutting energy use significantly.

Real-World Energy Savings

Variable frequency drives (VFDs) don’t just improve motor control — they deliver measurable ROI. In variable-load applications like mixing and dispersing, reducing motor speed when full output isn’t needed leads to exponential energy savings and lower maintenance costs.

Estimated VFD Conversion Value by Motor Size:

VFD Conversion Savings Table

Motor HP	Annual Runtime (hrs.)	Avg Load (%)	kWh Rate ($)	Est. Annual Savings (Energy + Maintenance)	Payback Period ($20K–$30K)	Cumulative Inflation-Adjusted Savings at Payback	Deferred Replacement Cost Avoided
30 HP	2,912	70%	$0.15	~$7,400	3–4 years	~$23,000	$35,000–$45,000
50 HP	2,912	70%	$0.15	~$9,300	2–3 years	~$29,000	$50,000–$65,000+
75 HP	2,912	70%	$0.15	~$12,400	2 years	~$25,000	$60,000–$85,000+
100 HP	2,912	70%	$0.15	~$15,600	1–2 years	~$32,000	$75,000–$100,000+

Motor HP: 30 HP

Annual Runtime: 2,912 hours
Average Load: 70%
kWh Rate: $0.15
Estimated Annual Savings (Energy + Maintenance): ~$7,400
Payback Period: 3–4 years
Cumulative Inflation-Adjusted Savings at Payback: ~$23,000
Deferred Replacement Cost Avoided: $35,000–$45,000

Motor HP: 50 HP

Annual Runtime: 2,912 hours
Average Load: 70%
kWh Rate: $0.15
Estimated Annual Savings (Energy + Maintenance): ~$9,300
Payback Period: 2–3 years
Cumulative Inflation-Adjusted Savings at Payback: ~$29,000
Deferred Replacement Cost Avoided: $50,000–$65,000+

Motor HP: 75 HP

Annual Runtime: 2,912 hours
Average Load: 70%
kWh Rate: $0.15
Estimated Annual Savings (Energy + Maintenance): ~$12,400
Payback Period: 2 years
Cumulative Inflation-Adjusted Savings at Payback: ~$25,000
Deferred Replacement Cost Avoided: $60,000–$85,000+

Motor HP: 100 HP

Annual Runtime: 2,912 hours
Average Load: 70%
kWh Rate: $0.15
Estimated Annual Savings (Energy + Maintenance): ~$15,600
Payback Period: 1–2 years
Cumulative Inflation-Adjusted Savings at Payback: ~$32,000
Deferred Replacement Cost Avoided: $75,000–$100,000+

How These Numbers Are Calculated

Runtime & Load: We estimate 2,912 annual hours (8 hours/day, 7 days/week) at 70% load — typical for industrial mixing applications.
Energy Savings: VFDs typically reduce energy use by 10–30%. For example, a 30 HP motor might save over 12,000 kWh annually — translating to ~$1,800 per year at $0.15/kWh.
Maintenance Savings: By removing wear-prone components like belts and gearboxes, VFDs save thousands per year in labor, downtime, and part replacement.
Payback Period: Based on an average $20K–$30K conversion cost, the breakeven point ranges from 1 to 4 years, depending on motor size.
Inflation-Adjusted Payback: Using a 3% inflation rate, total savings at breakeven range from ~$23,000 to ~$32,000 — showing how value compounds over time.
Deferred Replacement: VFDs reduce wear on both motors and mechanical drives, delaying capital equipment replacement. In many cases, this defers $35K–$100K+ in machine upgrades.

Calculate your own estimated savings with WEG’s VFD Calculator. Questions about VFD conversions? Don’t hesitate to contact us for assistance.

Bonus Savings: Rebates, Emissions, & ESG Value

Beyond the core energy and maintenance savings, utility companies offer cash rebates or incentives for installing energy-efficient upgrades like VFDs. These rebates significantly shorten your payback period — sometimes by thousands of dollars.

Even more, VFDs conversions support CO₂ reduction goals and contribute to your organization’s ESG reporting or corporate sustainability initiatives. Whether you’re looking to meet compliance standards, reduce your carbon footprint, or promote green practices, energy-efficient upgrades like VFD conversions check all the boxes (along with the real financial benefits!)

In Summary...

Upgrading your equipment doesn’t have to mean replacing it. We can convert your existing disperser or mixer into a VFD drive system quickly and efficiently, extending the life of your equipment while gaining performance.

Unlike energy rates or labor costs, a VFD investment is fixed. Every year you delay, costs go up — but your savings potential remains. VFD conversions aren’t just an upgrade; they’re a hedge against rising operating expenses, a tool for modernizing operations, and an investment in long-term plant efficiency.

“We upgraded two dispersers to VFDs last year with Schold’s help — the difference is night and day. Our operators love the quieter run, and we cut our energy use by over 15%. Wish we had done it sooner!”

– VP of Operations, Coatings Industry

“Our old pulley drives were becoming a maintenance headache. The VFD retrofit gave us better speed control and saved us thousands on repairs. Schold made the transition seamless.”

– Maintenance Manager, Adhesives Industry