How transformers can reduce energy costs and carbon emissions for businesses

Amorphous Core MAX transformer component

It’s not just retail consumers who appreciate a good bargain; businesses also seek value. However, in business, long-term considerations are crucial. The saying “you get what you pay for” rings true. Investing more in a high-quality product like power transformers can yield significant benefits over time.

Opting for cost savings during the initial purchase of a transformer can sometimes lead to higher expenses in the long run. Inefficiencies in operation can increase running costs, frequent breakdowns can result in downtime, and the overall life cycle and total cost of ownership of the transformer must be carefully considered. In such cases, prioritising cost alone may not be the wisest decision.

An overview of transformer development

The advent of revolutionary electrical power transformers can be attributed to the English scientist and inventor Michael Faraday. Faraday’s discovery of the Law of Electromagnetic Induction in 1831 laid the foundation for pioneering industrial experimentation over the next fifty years. This culminated in the creation of the first commercially successful power transformer in 1886 by William Stanley, who was employed by Westinghouse. Stanley also played a crucial role in advancing AC (alternating current) power technology, which supplanted the earlier DC (direct current) systems. Additionally, the collaboration between Frenchman Lucien Gaulard and Englishman John Gibbs in England led to the invention of a transformer and secondary generator, marking a significant milestone in the widespread adoption of AC power.

What are power transformers?

A power transformer operates on a principle similar to the transformer used for charging smartphones. The small transformer used for smartphones reduces the household AC (mains alternating current) voltage from around 220 volts to approximately 7 volts to charge the phone battery. However, the primary distinction, apart from their obvious size difference, lies in the fact that power transformers handle extremely high voltages, reaching up to 440kV.

The importance of power transformers

Power transformers, essential in conjunction with distribution transformers, ensure a safe and uninterrupted flow of electricity to both commercial establishments and residential households. They are critical because without them, electricity supply would cease, affecting everything from heavy industrial operations, medical facilities, and electric vehicles to the everyday appliances in our homes.

At the source, large power transformers step up generated power to ensure that the entire urban area supplied by the power station receives the necessary electricity to operate. Similarly, modern business equipment, ranging from heavy machinery to office computer systems, requires specific voltage levels provided by power transformers. Additionally, power transformers serve a secondary function by isolating devices from the main electrical supply, thereby preventing damage and minimising risks.

How old power transformers can cost you money

Increased Risk of Extended Downtime: Aging transformers are prone to sudden failures, potentially causing prolonged power outages at business sites. Difficulty in sourcing replacements can lead to downtime lasting from weeks to months.

Higher Operational Costs: Older transformers often operate less efficiently, resulting in increased electricity bills and maintenance expenses for businesses.

Frequent and Costly Repairs: Poor-quality transformers, affected by construction flaws or component issues, require more frequent repairs that add to operational expenses.

Long-term Cost Inefficiencies: Compared to newer, more energy-efficient models, ageing transformers can significantly inflate operational costs over their remaining lifespan, despite their lower initial purchase price.

Risk to Business Continuity and Reputation: Choosing lower-cost, lower-quality transformers can lead to premature failures, disrupting operations and potentially damaging the business’s reputation with customers.

Businesses are now under more pressure than ever to improve efficiency and reduce energy costs

Transformers with higher efficiency, like Powerstar’s advanced low-loss transformers, minimise energy losses, resulting in reduced operating costs. This not only benefits running expenses but also has a positive impact on the environment.

Cutting-edge Amorphous (ferromagnet metal) Core Technology is at the heart of Powerstar’s transformers and can provide up to 70% lower core losses compared to standard CRGO (Cold Rolled Grain Oriented Steel) transformers. By harnessing this technology, Powerstar enables significant savings in costs and carbon emissions. These potential savings of up to £12,500 per year are based on average historical customer savings achieved by upgrading from older transformers to Powerstar models, while also eliminating up to 14 tonnes of CO2 emissions. Moreover, Powerstar transformers deliver immediate reductions in energy costs and carbon footprint, making these business benefits compelling and essential.

Choosing the right power transformer – advantages of choosing a high-quality product

Improved Efficiency: Higher quality transformers are designed to minimise energy losses, resulting in lower operating costs and reduced electricity consumption.

Enhanced Reliability: They offer greater reliability with less frequent breakdowns and downtime, ensuring continuous operation critical for business continuity.

Longer Lifespan: These transformers tend to have a longer operational lifespan, reducing the frequency of replacements and associated costs.

Better Power Quality: They provide stable and consistent voltage regulation, protecting sensitive equipment from voltage fluctuations and ensuring optimal performance.

Environmental Benefits: Advanced technologies in higher quality transformers often contribute to lower carbon emissions, aligning with sustainability goals.

Cost Savings: Although they may have a higher initial cost, higher quality transformers typically deliver better long-term value through reduced maintenance and energy savings.

Compliance and Safety: They meet or exceed industry standards and regulatory requirements, ensuring safe and compliant operation.

How Powerstar can respond and help through smart technology transformers

Powerstar transformers offer several key advantages:

  1. Amorphous Core Technology: Experience up to 70% lower energy losses compared to conventional models, resulting in significant cost savings and improved operational efficiency.
  2. Integrated Remote Monitoring: Gain real-time insights into transformer performance with our integrated monitoring systems. This visibility allows proactive maintenance, minimises downtime, and optimises operational efficiency.
  3. Quality Assurance: Built to the highest industry standards including UL Quality Assurance (E472553), ISO 9001, ISO 14001, IEC 60076, and BS EN 61558, ensuring reliability and longevity.
  4. Short Lead Times: Efficient production and logistics ensure minimal disruption to operations, facilitating smooth deployment of our cutting-edge transformers.
  5. British Manufacturing Excellence: Designed and manufactured in Bromsgrove, Worcestershire, our transformers prioritize local sourcing and craftsmanship. This approach not only supports sustainability by reducing emissions associated with overseas transport but also ensures rigorous quality control at every stage of production.

Contact Powerstar today to learn how our innovative power transformers can meet your energy needs.