Powerstar identified PFF Group’s aging transformers as a a potential power resilience risk, as well as an area where their energy efficiency could be significantly bolstered.
High-speed, high-volume, 24/7 manufacturing is particularly susceptible to power disruptions.
The loss of production caused by a full blackout is so costly that a back-up power supply will be an almost inevitable requirement. However, the impact of a momentary power disruption or fluctuation can be equally costly in this industry. The Programmable Logic Controllers (PLCs), robot controllers, compressed air supplies, and multiple control systems which run these production lines will fail and reset with even a very brief dip in supply power. The time taken to restart production can be far greater than the length of the power disruption itself.
How to achieve power resilience for your manufacturing site
An Uninterruptible Power Supply (UPS) uses a battery energy storage system to ensure there are no disruptions to the power supply from the grid. By switching to the battery power supply in less than 0.01 seconds, on-site electrical equipment experiences no disruption in the event of a blackout, brownout, or other type of power disruption. Therefore, production continues without interruption.
Small UPS systems can be applied to individual systems or critical equipment. However, in the case of a high-speed manufacturing facility, the complexity and inter-connectivity of numerous systems means multiple small UPS systems would need to be implemented. A full site-wide UPS system can be installed to greater effect to prevent all on-site equipment from being disrupted, enabling production to continue uninterrupted.
Effective power management beyond the need for power resilience
Importantly, a UPS system with the scale to provide site-wide protection can also provide manufacturers with more functionality above and beyond power resilience. With the right control software and a robust energy strategy, a battery energy storage system can efficiently and intelligently manage on-site energy flows to simultaneously support net zero carbon objectives.
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“Industry 4.0 plus Net Zero”
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