The Challenge
The facilities operated a mix of legacy and newer electrical infrastructure supporting metal finishing lines, pumps, motors, and auxiliary systems. Electrical analysis identified elevated losses driven by poor power quality conditions, including excess amperage draw and inefficiencies across motor-driven processes.
These conditions increased energy consumption, contributed to unnecessary thermal stress on electrical components, and reduced overall system efficiency across multiple locations with varying operating schedules and equipment vintages.
The Solution
XCT deployed proprietary, patented power tuning technology and active power filters across six facilities in the client’s portfolio. The system dynamically optimized power quality by tuning electrical energy to a stable 60 Hz operating condition, allowing motors to perform the same work while drawing less amperage.
Each installation was custom-engineered for the site and completed over an approximately four-week deployment period without disrupting ongoing operations.
The Results
Post-installation performance data demonstrated consistent and material improvements across all locations:
- Reduced amperage draw on motor-driven equipment
- Improved electrical efficiency across production systems
- Measurable reductions in total energy consumption
Across the six facilities, the project delivered sustained energy savings while improving overall electrical system performance.
The Impact
The optimized power quality environment reduced electrical stress on equipment, supporting longer useful life and lower degradation rates across critical assets. Over a ten-year horizon, the project is expected to deliver meaningful energy savings while improving operational reliability across the client’s national footprint.
