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Polestar is Europe’s largest independent print company whose mission is to be the leading content delivery company with expertise and experience to manage clients content delivery requirements.

Polestar Sheffield, the site at which the Powerstar Voltage Optimisation system was installed, is one of the few elite printing sites in Europe, producing 2.5 million catalogues, national newspapers, magazines, brochures and supplements every 24 hours. The $150m purpose built gravure facility is Polestar’s largest ever single investment, and is still today the most advanced and competitive gravure plant in Europe.

The challenge

Polestar’s Environmental Steering Group meets regularly to consider all environmental aspects, which includes those relating to paper, ink and energy management. All printing sites are in the UK Government’s Climate Change Levy Agreement process, and Polestar was the first major printer to sign up to the energy efficiency process then run by The Carbon Trust on behalf of the Government.

The site was having harmonic issues and Powerstar was asked to analyse the harmonic distortions within the factory while each individual line was shut down as to clearly identify the source of the harmonic distortions within the factory.

The solution

Following installation of the Powerstar voltage optimisation system, voltage levels on site were reduced resulting in an energy reduction of 8%. Powerstar also significantly reduced the total current and total voltage harmonics on site by 50% and 10% respectively.

  • Reduction in annual energy consumption: 8.0%
  • Reduction in total current harmonics: 50.0%
  • Reduction in voltage harmonics: 10.0%


View the Case Study PDF Here


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