High-performance drive technology with variable frequency drives from Lenze for recycling and bulk material plants

Recycling and bulk material processes place extreme demands on drive technology. High load peaks,abrasive materials,dusty environments, and fluctuating material flows require high-torque, robust, and reliable drive systems – while simultaneously facing pressure to reduce energy and operating costs.

What application are you looking for?

Typical challenges

  • High mechanical stress on motors and gearboxes
  • Highly fluctuating torques and frequent start-up cycles
  • Continuous operation with high energy consumption
  • Harsh environmental conditions indoors and outdoors
  • Space and cost constraints during installation and maintenance
Conveyor belt moves gravel onto a large gravel pile outdoors.

Your benefits with Lenze VFDs for bulk material and recycling machines

Our frequency drives cover a wide power range from 0.25 to 132 kW and are available in IP20, IP55, or IP66 versions for control cabinet, wall, or motor mounting. They are designed for harsh environmental conditions in recycling and bulk material plants and can be reliably used at temperatures ranging from -30 to +60 °C.

The i550 motec offers particularly compact, motor-mounted solutions up to 45 kW—ideal for limited installation space and decentralized applications.

The i650 motec integrates PLC functionality, IO-Link master, and energy recovery directly into the drive. This significantly reduces cabinet space requirements, cabling, and engineering effort, lowering the total cost of the system.

Developed in Switzerland and manufactured in Germany, the USA, and China, Lenze variable frequency drives stand for consistent quality standards and quality standards with local support worldwide.

Several Lenze i550 cabinet drives in a control cabinet and a close-up of an i550 cabinet drive

Compact power for your control cabinet

i550 cabinet

IP20 | NEMA 250 Open Type

  • Requires 40% less space: Compact drives support a streamlined control cabinet design with side-by-side mounting without reducing performance
  • Overload capacity of up to 200% allows for a more compact drive selection
  • Smooth operation with S-ramps
  • Supports asynchronous and permanent magnet motors
  • Supports IT networks for mobile installations
  • Integrated holding brake control
  • Dynamic braking with integrated brake chopper
  • Keypad user units [m/s]
  • Configurable shutdown positioning as a stop method
  • Supports ATEX installation by connecting an external ATEX temperature protection relay to the i550 STO module (SIL 3 / PL e)
  • Generic functionality for auxiliary drives such as pumps, fans, etc.: PID control, power failure bypass, flying restart, etc.

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Decentralized VFDs for harsh environments

Overview of the i550 protec series from Lenze.

i550 protec

IP66 | NEMA 4X
IP55 | NEMA 12

  • Robust construction: IP66 and NEMA 4X protection ratings, suitable for outdoor use and capable of withstanding harsh environmental conditions from -30 to +60 °C
  • 60% more compact than comparable solutions on the market
  • Optional: Customizable extension box for customer-side installation of indicator lights, switches, and disconnect switches.

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Lenze i550 / i650 motec

i550 / i650 motec

IP66 | NEMA 4X
IP55 | NEMA 12

  • Integrated "global" DC power supply for the holding brake, configurable to 180 VDC/215 VDC, independent of the mains voltage
  • Dynamic braking with environmentally friendly energy recovery to the grid that is easy to integrate
  • Extended auxiliary voltage: Internal 24V supply up to 0.4 A; external 24 or 48V up to 1 A
  • Connectors for easy installation
  • i650 motec with integrated Codesys-based PLC and IO-Link master functionality, Extended Safety, and Basic Positioning

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Powerful and easy-to-use drive package consisting of a gearmotor and variable frequency drive

The package consisting of the g500 gearmotor and i550/i650 frequency drive is designed for high loads and dynamic requirements in recycling and bulk material handling systems.

The following are used:

  • Bevel gear motors
  • Spur gear motors
  • Shaft-mounted helical gearmotors

Torques up to 20,000 Nm are possible.

The motors are available in energy efficiency classes IE3, IE5, or IE6 and can be configured either as a standard 50/60 Hz version or as a compact 87/120 Hz variant. Compared to conventional 50 Hz technology, the 120 Hz variants allow significantly more compact gearmotors while maintaining the same power output. This saves on investment costs and weight.

In combination with the i550/i650 frequency drive, the IE5 system enables up to 250% overload capacity, as well as sensorless positioning.

For simple, decentralized applications, the Smart Motor m300 up to 1.36 kW, featuring up to five fixed-parameter speed stages, rounds out the portfolio.

Design is performed using Lenze Engineering Tools for a load- and energy-optimized drive configuration.

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Illustration of the Lenze package consisting of g500 gearmotor and i550/i650 VFD

Optimal applications for drive technology in recycling & bulk materials

Lenze VFDs are ideally suited for use with a wide variety of materials in the handling of gravel and stones, asphalt, concrete, plastic granules, grain, seeds, feed technology, food, or in the recycling industry, such as household waste, biomass waste, construction debris, plastic waste, and electronic scrap.

Several plastic bottles on a conveyor belt with a person in a high-visibility vest and helmet in the background

Conveyor technology

Belt, chain, and screw conveyors for bulk materials, waste, stones, and recycled materials require robust drives that are easy to install and ensure reliable continuous operation. Optimized system technology can be implemented thanks to integrated functions such as holding brake control, regenerative capability or even sensorless positioning with Lenze IE5/IE6 motors.

Close-up of a shredding machine with several rotating metal rollers and open housing

Shredding, Crushing & Screening

Shredders, crushers, trommel screens, and screening systems require frequency drives with high overload capacity, controlled startup, and safe shutdown.

Close-up of an industrial sorting machine with several chambers full of small round objects and a control unit superimposed at the bottom right

Sorting, Cleaning & Drying

Vibration motors, fans, blowers, and pump drives benefit from efficient speed control and flexible deployment: decentralized or in a control cabinet, with control simply I/Os or powerful control via a wide variety of fieldbus technologies.

Large construction machine on gravel surface with raised conveyor belt

Mobile & Open-Field Systems

Mobile recycling and bulk material systems in open-field applications are increasingly electric rather than hydraulic. This offers several advantages:

  • Higher productivity through more precise control
  • 30% less noise (2–5 dB)
  • Lower maintenance costs and fewer breakdowns

FAQs – Frequently asked questions

What challenges do recycling and bulk material processes pose for drive technology?

Recycling and bulk material processes place extreme demands on frequency drives, as they operate with high load peaks, highly fluctuating torques, frequent start-ups, and abrasive materials. Additionally, dust, moisture, and temperature fluctuations affect motors and drives.

For which drive tasks are Lenze solutions suitable in recycling?

Lenze drive solutions are suitable for all key drive tasks in recycling and bulk material plants, particularly for conveying, shredding, crushing, screening, sorting, cleaning, drying, and mobile recycling plants in open-field applications. They are designed for high loads, continuous operation, and changing process conditions.

Are Lenze variable frequency drives and motors suitable for dusty and harsh environments?

Yes, Lenze drive technology is specifically designed for harsh industrial environments. With protection ratings up to IP66, they are suitable for dusty, damp, and high-stress applications ­­­­– both indoors and outdoors in recycling and bulk material facilities.

Can hydraulic drives be replaced by electric ones?

Yes, hydraulic drives can be replaced by electric drive systems in many recycling and bulk material facilities. Electric solutions from Lenze offer advantages such as lower energy consumption, reduced maintenance costs, quieter operation, and better controllability – especially in mobile systems.

How do Lenze variable frequency drives contribute to energy efficiency?

Lenze VFDs increase energy efficiency through demand-based speed control, efficient motors, and optimally matched drive systems. This significantly reduces energy consumption and operating costs in recycling and bulk material processes.

Does Lenze provide support in the design of drive systems?

Yes, Lenze supports machine builders and operators with engineering tools, application expertise, and technical consulting. The goal is to provide an optimally designed drive solution tailored to the specific requirements of recycling and bulk material applications. By utilizing application data such as overspeed and torque curves, the optimal solution in terms of cost, size, durability, and energy efficiency can be identified.

How can Lenze’s 120 Hz technology be used to build more compact gearmotors?

The size of a motor is defined by its torque. Higher speeds, on the other hand, do not require a larger installation space. For example, by increasing the speed from 1,500 rpm (50 Hz) to 3,600 rpm (120 Hz), the power can be doubled with almost the same size and weight. By adjusting the ratio of the gearbox factor, the customer gets the same performance data with a drive unit that is half the size.


The disadvantage of this solution is that the operation of a 120 Hz motor is only possible with a VFD. On the other hand, such a VFD also offers the advantages of considerable energy savings, higher overload operation and smoother starting for the mechanics.

How can Lenze with achieve sensorless positioning with IE5 motors?

Conventional PM control methods control the PM motor in the lower speed range up to approx. 10 % of the rated speed with a frequency-dependent current and only then switch to vector control. This is sufficient for pump and fan applications, but is less suitable for mixers and materials handling technology with high starting torques. The PM control in a Lenze IE5/IE6 drive system is different, as it always knows the exact rotor position from speed "0" to max. 4,500 rpm with an inaccuracy of a few degrees and can offer up to 250 % overload at speed 0. This leads to more performance with less energy loss.

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