“When you connect the motor, just use the thinnest cable – it’s cheaper and will do.” During his training as a mechatronics engineer, Maximilian Christians, now Research Engineer Advanced Technology at LAPP, often heard this phrase from his masters. But even back then he asked himself the question: is less really always better? Thinner cables save on materials and are cheaper to buy, but they cause higher power losses. The question of whether this would not be more expensive in the long term never left Maximilian Christians.
After studying mechanical engineering, he investigated this question at LAPP, the global market leader for integrated solutions and branded products in the field of cable and connection technology – today he knows that the common rule of thumb “thinner cable equals less material and therefore lower costs” does not go far enough. His research on the topic of sustainability revealed that even if cables with a larger cross-section require more material to manufacture and therefore initially cost more, they can save emissions and energy costs over their life cycle thanks to lower power losses. “In a future characterised by sustainable change, rising energy prices and CO₂ levies can become a decisive factor for users when it comes to making efficient and sustainable decisions,” explains Maximilian Christians.
Maximilian Christians
Research Engineer Advanced Technology
Maximilian Christians absolvierte seinen Master of Science in Maschinenbau an der Hochschule Bochum. Bei LAPP stieg er als Research Engineer Advanced Technology ein und engagiert sich für technologische und nachhaltige Innovationen. Als Teil des Vorentwicklungsteams veröffentlichte er die Ergebnisse seiner Forschung in einem Whitepaper mit dem Titel „Wie größere Leiterquerschnitte Kosten und CO2-Emissionen senken“.
Initial costs vs. long-term effect
It was clear from the outset that a thinner cable generates more heat due to its higher electrical resistance, which leads to avoidable power loss. The thicker the cable, the lower this resistance – the current can flow unhindered without a large proportion of the energy being converted into heat. This is particularly relevant for industrial applications in which high currents flow and the power loss increases disproportionately with increasing load. Cables with a larger cross-section therefore not only save energy, but also reduce the heating of the connection, thereby improving the operational reliability and service life of the entire configuration
However, a cable with a larger cross-section requires more resources such as copper, which increases the initial production and acquisition costs and initially leads to higher CO2 emissions than a thinner cable. “Against this background, the solution cannot be We take the thinnest cable to save money, or the thickest to protect the climate,” emphasises Maximilian Christians. “Rather, it’s about calculating the optimum ratio. As part of the LAPP pre-development team, I was finally able to develop a sound method for this.”
Calculation model shows savings potential
Maximilian Christians has developed a calculation method that takes into account not only the acquisition costs but also the operating costs over the entire service life of the cable – the so-called total cost of ownership (TCO). His investigations show that the purely standardised minimum cross-section is often not the economically and ecologically optimal choice. For example, with a cable length of 50 metres and a three-phase network at 16 A rated current, the standard-compliant minimum cross-section is 2.5 mm². However, if you consider the long-term energy costs, an average of 6 mm² would be the more economical choice. If the CO2 balance over the entire life cycle is also taken into account, an even larger cross-section of 16 mm² is the most sustainable solution. The optimum cable average therefore depends on several factors, such as the rated current, the service life and the electricity mix. “Companies should pay attention to this when selecting their cables,” explains Maximilian Christians. “Even today, a well-founded decision on the optimum conductor cross-section can bring considerable savings in CO2 emissions and costs.”
LAPP with a comprehensive commitment to sustainability
The choice of the optimum cable cross-section is one of many sustainability levers at LAPP. At the Hannover Messe, LAPP will be demonstrating how choosing the optimum cable cross-section can contribute to CO2 reduction and cost efficiency. For many machine manufacturers, the correct cable dimensioning has been an underestimated lever for reducing CO2 emissions. Maximilian Christians is convinced that LAPP will attract a great deal of interest with this topic: “It is a perfect example of how economic efficiency and climate protection can go hand in hand. The long-term reduction in energy costs also means a more sustainable use of resources.
And because sustainability must be measurable, LAPP integrates its research results into an emissions and TCO life cycle calculator that customers can use to determine the optimum cable cross-section for their requirements. In this way, LAPP supports its users in making sustainable investment decisions that offer both ecological and economic benefits. For Maximilian Christians, one thing is certain: “This concept is a building block in LAPP’s comprehensive sustainability strategy with which we are further expanding our pioneering role in the industry
LAPP is taking a further step in this direction with the publication of the Product Carbon Footprint (PCF), which creates transparency about CO2 emissions throughout the entire production cycle – from raw material extraction to production and logistics. In addition, engineers at LAPP are continuously developing innovative, sustainable materials, such as the bio-based ETHERLINE® bioP Cat.5e data cable and the bio-based EPIC® connectors, which significantly reduce the use of fossil raw materials. “Sustainability is in LAPP’s DNA – you can see that in many areas,” explains Maximilian Christians. “From pre-development at the Stuttgart site, through development and production, to our logistics, where LAPP reduces emissions with optimised shipping routes and partially recycled packaging material.” With a smile, he adds: “And I’m personally pleased that I can now prove to my former masters with figures that the thinnest cable is not always the best choice.”
LAPP Whitepaper: “How larger conductor cross-sections reduce costs and CO₂ emissions”
Discover in our whitepaper how choosing larger conductor cross-sections in cables can not only reduce operating costs but also lower CO₂ emissions. Learn about the long-term economic and ecological benefits through reduced energy losses and efficient utilisation.
Download LAPP Whitepaper