The Challenge
The facility operated multiple motor-driven processing systems supplied through several motor control centers (MCCs) fed from primary switchgear. These systems included pellet mills, hammer mills, and other mechanically intensive equipment used throughout the production process.
Electrical performance analysis identified elevated reactive power and inefficient current flow within the facility’s electrical network. These conditions contributed to higher apparent demand, reduced electrical efficiency, and increased thermal stress on motors and supporting electrical infrastructure.
Because the facility operates under continuous production schedules, any solution needed to improve electrical performance without altering production throughput, equipment operation, or manufacturing processes.
The Solution
XCT deployed its proprietary, patented XECO power quality system integrated directly within the facility’s existing electrical distribution infrastructure and MCC network.
The system dynamically tunes electrical energy at the distribution level to reduce reactive power, apparent demand, and non-productive current while maintaining identical mechanical output from the facility’s motor-driven equipment.
The installation required no changes to production equipment, operating schedules, or manufacturing processes and integrated seamlessly with the existing electrical system.
The Results
Post-installation measurements demonstrated measurable improvements in electrical performance:
• 13.5% reduction in estimated monthly electrical costs
• Approximately 10% reduction in total energy consumption (kWh)
• Approximately 21.1% reduction in apparent demand (kVA)
• Power factor improvement from 67.9% to 78.8%
• Production throughput remained effectively constant during testing periods
These improvements reflect a cleaner, more efficient electrical operating environment across the facility’s motor-driven processing systems.
The Impact
By improving power quality and reducing reactive power across the electrical distribution system, the facility enhanced electrical efficiency while reducing electrical stress on critical equipment.
The project delivered measurable reductions in electrical demand and operating costs without disrupting production operations or requiring modifications to process equipment.
The results demonstrate a scalable approach for industrial manufacturing environments with high motor density, including feed production, food processing, material handling, and other mechanically intensive operations seeking to improve electrical performance and operational reliability.
