Smarter, Greener, Stronger: Berg Propulsion on Fuel Efficiency and Future Shipping

Berg Propulsion has been an innovator in marine propulsion technology since its foundation in 1912. Today, its portfolio includes controllable pitch propellers, azimuth and tunnel thrusters, control systems, various electrical integration components combined with the integrated control and energy management systems to optimize propulsion performance overall.

In recent years, Berg has focused with increasing intensity on energy efficiency, whether by modelling, designing and developing new or upgraded propulsion solutions, or by devising integrated systems to optimize performance for different operating profiles. As well as enhancing the efficiency, fuel economy and sustainability of newbuilds, Berg has also developed a range of retrofit solutions to help existing ships outperform IMO targets for carbon emissions and perform profitably for years to come.

Sustainability and energy efficiency are top priorities for shipowners today. How is Berg supporting decarbonization efforts through its products and solutions?

Shipping’s shift to new fuel types and alternative energy sources such as battery power, wind turbines and fuel cells are highly significant changes to the industry. To enable this and overcome the higher energy cost that is associated with these installations, an optimal propulsion system is one of the key requirements. By optimizing the propulsion system, the resulting efficiency gains help transition to new fuels and energy carriers. For Berg, this is a great opportunity to demonstrate its experience in vessel and propulsion optimization..

Berg also has a special energy efficiency team which focuses on analyzing existing vessels and offering solutions to optimize performance and thereby bring an ageing fleet up to  efficiency standards that are not too far from equivalent new builds. Berg recommends one of more of the following options:

• We have developed Dynamic Drive adaptive thrust and fuel optimization software, which can be retrofitted to enhance performance when Berg Propulsion’s MPC800 control system is already installed or retrofitted.
• Propeller blade optimization: Berg analyzes a vessel’s existing/future needs using advanced simulation tools/3D scanning, then models blade profiles to optimize performance
• Propeller blade replacement: Berg has even developed a solution for propeller blade replacement to fit with any hub.
• Control system replacement: Retrofitting the Berg MPC800 control system, adding Net Frequency Stabilizers and modifying main engines to run at variable rpm can yield significant efficiency gains for CPPs/thrusters.
• Where Berg’s MPC800 system is installed but an owner needs enhanced IMO Energy Efficiency for eXisting Index performance, Berg offers Energy Power Limitation ‘EPL for EEXI’ software.

Can you tell us more about your latest innovations in propulsion systems, and how these are helping vessels reduce fuel consumption and emissions?

As noted, innovations are being made in software, systems integration and physical equipment. In Berg’s case, examples include:

• Further development of Dynamic Drive software, whose algorithm identifies the best possible rpm/pitch combination to enhance propulsion and engine efficiency at a given lever/thrust setpoint. This optimizes brake power from the propeller to deliver fuel savings on the main engine consumption and allows the operator to set an upper limit to vessel speed or the engine fuel consumption rate. Exceeding the limit will automatically result in a thrust reduction until the limit is met. Dynamic Drive can achieve 10% in fuel savings (20% in some conditions).
• Development of ‘OpWind’ software, which leverages Dynamic Drive to help crews combine the operation of sails and propellers in the most efficient way in various sea conditions. By integrating data for the contribution being made by wind power to propulsion, OpWind adjusts propeller pitch and speed to optimize energy management.
• Where control, power distribution and energy management is concerned, fuel economy and emissions reduction are served by better integrating main engine, battery and shore power sources to optimize vessel efficiency in all scenarios. A recent typical installation for forward-looking owner includes electric motors with permanent magnet technology run by Berg’s MPC800 Control System, and provides continuous dynamic optimization of propeller rpm/pitch/vessel speed. In this case, the setup is also future proof to integrate bigger batteries and fuel cells. Integration is based on dual DC-Hubs which control propulsion motors, batteries and the inverter for the main switchboard and deliver variable speed to optimize genset energy use.
• Berg also continues to enhance the hydrodynamic performance of its hardware, with advanced simulation tools being used to develop new propeller geometries, for example. In one recent project, propeller blades optimised for ship operations at 12 knots resulted in 50% higher efficiency.

From your global sales perspective, which markets are showing the strongest interest in retrofitting or upgrading propulsion systems?

Berg works with ship owners and shipyards all over the world on newbuilding and retrofit projects but, as far as upgrading propulsion systems is concerned it is fair to say that the majority of our projects to date have originated with owners in Europe.

Berg Propulsion often highlights the importance of lifecycle support. Could you elaborate on your approach to after-sales service and customer care?

Our ambition is always to be as approachable as possible and to create long term  relationships with end-users that help them meet their own business objectives. Central to doing so – as a supplier of critical equipment, is to remain responsive, innovative, and ready to be proactive in assuring our systems align with customer requirements on up-time. We invest in strong inhouse service engineering and in technical support capacity at strategic locations. Our analytical work is essential and it is also providing the basis for  more innovative solutions in pipeline to further improve our life cycle support.

Are you seeing an increased demand for hybrid or electric propulsion solutions, and how is BERG responding to this trend?

Yes, we are increasingly seeing owners preferring hybridized setups, due to their responsiveness and ability to optimize energy from different sources – gensets, shaft alternators, batteries for load balancing and shore power connections. Owners want flexibility during operations and real life performance that matches  claims made, and that demands a range of solutions from Berg which integrate capabilities meeting the needs of different vessels and conditions.

How important is the Mediterranean market — and Cyprus in particular — for Berg Propulsion? Do you have any plans for expanding your presence in the region?

The Mediterranean area is important to Berg from various perspectives. Many leading industry owners and operators are located in this area, including some which have been frontrunners in developing ways to reduce exposure to EUs ETS costs. Including Turkey, the region also brings in significant yard capacity that is equipped to undertake overhaul projects as well as new building. In this context,, our offers covering upgrades and retrofits become highly relevant in this area.

What are your main goals and focus areas for the remainder of 2025 and beyond?

We intend to continue focusing on innovation and on investing in solutions that anticipate the needs of our customers. A recent example of this stance from Berg has been its offer of shipping’s first opportunity to select propeller shafts produced using the climate-neutral GreenForge® process. We believe the maritime sector’s exposure to carbon pricing is just starting and that sustainable alternatives to conventional steel production will be a future necessity.

Three new Ro-Ro vessels from Louis Dreyfus Armateurs (LDA) are distinguished by sail power, but their engine-driven propulsion systems from Berg feature propeller shafts made from recycled scrap steel formed by Björneborg Steel’s GreenForge® process. The process has been independently verified to reduce CO2 emissions by 95% compared to standard methods, with the remaining emissions offset to ensure full climate neutrality.

Finally, what key message would you like to share with shipowners and operators considering upgrades or new builds?

Modern propulsion technologies provide greater reliability and redundancy compared to older systems. This not only enhances the safety of the crew but also reduces downtime caused by mechanical failures that could potentially cause costly delays.

Besides reduced fuel consumption and emissions levels, retrofitting and upgrades can lead to lower maintenance costs and fewer spare parts requirements – ultimately offering operational benefits to safety as well as and compliance with the upcoming environmental regulations.

Get in touch with our propulsion experts here.