Kaysersberg Plastics - Gloucester

Kaysersberg Plastics – powerPerfected 

Kaysersberg Plastics in Gloucester is one of eight European sites for Kaysersberg Plastics, part of D.S. Smith Plastics Ltd. The site at Gloucester includes both offices and a manufacturing plant, and is supplied by three transformers.

The challenge, the solution and the savings

The electrical load in the manufactoring plant was dominated by the process machinery for their products, but also included lighting - which was the principle load in their offices. Following a process of evaluation to confirm both the level of optimisation and suitability of the Kaysersberg site, a 560kVA powerPerfector unit was installed in the spring of 2006. A further two units, 420kVA and 560kVA, were installed in the summer of 2007.

Topline results

We were delighted to see savings in the region of 11% in kWh consumption at Kaysersberg Plastics. This equates to an annual saving of 336,000 kg of carbon emissions. powerPerfector technology also made sure that the site now operates more efficiently, benefits from improved power quality and is protected against common transients (power spikes). All this was achieved with a minimum of disruption – important to any manufacturing business. With absolutely no moving parts, the powerPerfector units need no maintenance beyond the statutory 5 yearly checks required of all electrical equipment.

Voltage Power Optimisation. The less obvious benefits

Reduced maintenance, longer life
All electrical equipment has an optimum voltage at which it works best. A powerPerfected supply delivers that optimum and reduces the strain on your electrical equipment, leaving it to work more reliably and for longer.

Better quality power supply
Some things you may have accepted for years as product faults can turn out to be caused by a poor quality power supply. For instance, the life of incandescent light bulbs is almost doubled when the supply voltage is optimised. Now imagine that in relation to an IT network or an expensive piece of manufacturing equipment.

Missing the penalty kick
Power factor penalty charges – which are now uncapped in the UK – can be avoided if your power factor is above 0.95. If your power factor is at around 0.9 at the moment, powerPerfector could remove your exposure to these charges by improving the electrical efficiency of your site.

Lower harmonic distortion and reduced neutral currents
powerPerfectors are able to filter harmonics on the mains incomer. Harmonic distortion is on the increase and can lead to random failures of electronic equipment – particularly computers.

Protection
Common transients – very brief spikes in voltage from the grid – are eliminated by powerPerfector. Transients at this level can cause catastrophic damage to equipment, but smaller, more common transient events will also shorten the life expectancy of electrical equipment over time. Each installation ensures that Kayserberg may no longer risk electronic failure in the site from a transient that would put them out of business for days. Kayserberg are now protected.