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Printing & Packaging

Costs Avoided, business grows and investment payback << 1 Year

A large privately owned printing and packaging company in Northern Florida experienced a significant number of unplanned stoppages to their production equipment, which not only caused loss of production but incurred substantial maintenance costs and damage to equipment.

The company has a number of very large high speed printing presses plus high speed block cutting, folding and gluing machines used in the manufacture of high end packaging materials. The company operates as a 24/7 operation with limited planned shutdowns only two or three times a year. The company prides itself on short delivery times to its customers and for many years has developed an enviable record of on time delivery.

The cause of the unplanned stoppages was identified as numerous short term variations in the supply voltage to the plant. These events, voltage sags, frequently lasted for only a small fraction of a second but were enough to cause high speed machinery to malfunction or stop. It could then take several hours to clear product from the machines, repair any damage, recalibrate the process, restart and reach normal operational speeds.

The plant is supplied at medium voltage, 26kV, from an overhead utility line and has a dedicated transformer providing 2500kVA at 480V. In stormy weather unplanned stoppages occurred on a weekly basis or worse.
Unfortunately, the local electrical utility was only able to provide limited relief from these problems and advised the company to look at voltage sag correction equipment. They suggested their customer should examine, among other potential solutions, the Active Voltage Conditioner (AVC) technology supplied across North America by Omniverter Inc.

The utility had installed sophisticated electrical metering at the site to monitor the depth and duration of the voltage variations. The company was able to access this information and shared it with Omniverter so that a variety of solutions could be evaluated using specialized emulation software.
The result of this analysis was to select an AVC model which would correct over 93% of all the voltage events recorded.