How much power does a CNC gear hobbing machine save over a conventional one?
The BEE and SAMEEEKSHA report for the Bangalore machine tools cluster shows specific energy falling from 3,126 to 2,344.5 kWh per tonne, a saving of 68,928 kWh a year, shown as 51.7 tonnes CO2. That annual figure assumes output rises 1.75 times.
The per-tonne saving
3,126 minus 2,344.5 is 781.5 kWh per tonne, or 25%. The report credits this to hob speed: carbide-tipped hobs run at about 160 metres a minute against 16 for the HSS cutters of conventional machines, so each part takes 5 to 10 times less time.
The annual saving rests on an assumption
The report takes output from 50.4 to 88.2 tonnes a year, 1.75 times more, on the same machine. 781.5 x 88.2 is the 68,928 kWh. If your output does not rise, the saving is smaller.
Other facts in the report
- Cluster: 100 units in Bangalore; 30 studied and 10 audited in detail.
- Installation: 4 to 5 days, with no effect on production.
- Life: up to 20 years with proper maintenance.
Worked CO2, with and without the output assumption
- With the report's output rise: 68,928 kWh x 0.675 kg per kWh (FY 2025-26) = 46,526 kg, or 46.5 t. The report shows 51.7 t, about 0.75 t per MWh.
- Output unchanged at 50.4 tonnes: 781.5 x 50.4 = 39,388 kWh.
- At 0.675: 39,388 x 0.675 = 26,587 kg, or 26.6 t.
The report dates from 2010; check the current grid factor for your bill year.
What Senseible does here
Senseible reads electricity bills into a monthly kWh record, so output and energy per tonne can be compared before and after a machine change.
Last reviewed 2026-11-03.