At Mauser Packaging Solutions, our engineers have freed up as much as 500 amps of additional grid capacity by targeting grid contamination. By eliminating blind current penalties and installing active filtering, we guarantee a healthy installation ready for further scaling up without heavy grid connection investments.
At Mauser Packaging Solutions' Oosterhout production site, six transformers and an extensive machine park with 20 blowing machines and 19 injection moulding machines form the heart of the operation. However, the presence of blind current led to monthly fines from the energy supplier, while harmonic contamination from specific controllers even spilled over to other main distributors. This invisible grid contamination posed a direct risk to continuity and limited the ability to further increase production capacity at the site.
The challenge for installation manager Reinier Goorden was therefore twofold: stopping the unnecessary cost and creating sufficient power for new machines without a lengthy process for a heavier connection. In an environment where downtime is not an option, Mauser was looking for a partner that not only advises, but takes full responsibility for a healthy installation.
To identify the exact cause of contamination, our engineers carried out a comprehensive Power Quality measurement on 13 outgoing feeders. Using 'continuous waveform recording', we recorded every detail of the electrical currents for an incontrovertible diagnosis. This showed that for specific feeders, harmonic power was even higher than reactive power, indicating a heavy load on components and an increased risk of failure.
This approach enables us to uncover the complex dependencies between machines and transformers. Instead of treating symptoms, we mapped the entire installation, including the impact of harmonics on transformers. This factual underpinning provides evidence for our improvement plan, where each proposition rests on hard measurement results to ensure plant safety at Mauser.
Based on the analysis, our engineers implemented harmonic filters at transformer level to tackle pollution directly at the source. This active solution neutralises harmonics and improves the Cos Phi, making the plant operate more efficiently and blind current penalties a thing of the past. Through this proactive intervention, we reduced the physical load, which directly resulted in a huge gain in available power.
The transformation to stable plant enables Mauser to utilise up to 500 amps of additional capacity within existing infrastructure. In addition, installed Power Quality meters provide continuous insight, allowing Mauser to now save energy even at the machine level by sizing processes smarter. The plant has thus been technically restored and fully prepared for a future of safe and uninterrupted growth.
A healthy plant is the foundation of your production. At Mauser, we have proven that technical expertise leads directly to lower costs and extra capacity. Our engineers take full responsibility from diagnosis to delivery, so you can rely on maximum operational reliability.
HyTEPS
Beemdstraat 3
5653 MA Eindhoven
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