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Packaging Manufacturer


The client is a global leader in the packaging industry with operations in over 40 countries and 250 sites worldwide.

They specialise in developing and producing responsible packaging for food, beverages, pharmaceutical, medical, home and personal care, and other products.

Due to the size and scope of the company, it is exceptionally conscious of its sustainability credentials and produces an annual sustainability report to showcase its commitment.


As a result of this commitment, the company continuously searches for opportunities to make improvements to their energy intensive production processes.

The company realised its high voltage (HV) infrastructure was ageing and highlighted it as an area that efficiency improvements could be made.

To confirm this, the client chose Powerstar to perform a site survey because of its experience and reputation for delivering smart energy solutions. Evaluation revealed that significant energy savings could be made on both the HV and LV sides of the supply.

Due to the continuous operations of the site, it was integral that the project was carefully scheduled to minimise disruption to the its production processes, and Powerstar worked closely with the client to ensure downtime was minimised.


Powerstar recommended replacing three ageing HV CRGO transformers with Powerstar HV MAX systems, combined super low loss amorphous core transformers with integrated variable voltage optimisation technology.

By upgrading the transformers, the solution provides savings by minimising the losses inherent in older transformers, whilst the voltage optimisation technology regulates the incoming voltage and maintains it at a constant level to provide further reductions to costs, consumption, and carbon emissions.


Post installation analysis of the site has shown an electricity consumption saving of 7 – 9%, depending on the site’s production.

This has resulted in an approximate annual CO2 reduction of 400 tonnes, assisting the company’s sustainability credentials whilst delivering significant electricity cost savings.

  • Annual Consumption Saving: 7 – 9%
  • Annual CO2 Reduction: 400 tonnes

View the Case Study PDF Here


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