This paper presents harmonics behaviour of phase current waveform of trapezoidal BLDC motor drive in 120° conduction mode. Based on the analysis, current switching PWM for 120° mode with selective harmonics elimination is proposed for loss minimisation of brushless DC motor drive system. The proposed control technique uses optimal pulse width modulation to optimise core and copper loss at different sets of loads and speeds. This scheme includes UPFC-based front end converter using double band hysteresis control which improves power quality of conversion. The effectiveness of new control scheme is explained through simulation based on MATLAB/Simulink R2014b. The control scheme is verified on prototype 350 W brushless DC motor drive system.