FOOD & BEVERAGE
can improve operating efficiency significantly. As compared to a traditional CRGO model, a modern alternative can lower core losses during transmission by up to 70 per cent, reducing manufacturers’ Scope 2 emissions and thus reducing customers’ Scope 3 emissions, where major supermarkets are now focused when awarding contracts.
IMPROVED ENERGY MANAGEMENT IN ACTION
Voltage Optimisation unit
Business Programmes at WRAP, noted, “On the supply side, the pathway to net zero depends on the rapid decarbonisation of electricity, heat and transport infrastructure...” IGD’s Chief Executive, Sarah Bradbury, emphasised that, “This is the start of a journey together... We need a different approach, one that involves the whole end-to-end supply chain, a more aligned dialogue across industry...”
SMARTER ENERGY MANAGEMENT FOR A COMPETITIVE ADVANTAGE The Carbon Trust suggests an approach to breaking down barriers to decarbonisation, “Your business cannot do everything at once. Focus first on the areas that can drive the greatest impact, based on a rigorous assessment of the risks and opportunities...” For food and drink manufacturers and their
suppliers, where investment in, or upgrade of, energy management technology forms part of a sustainability strategy, there can be cost- savings through reduced energy usage. Avoiding energy waste with voltage
optimisation: Voltage Optimisation (VO) enables incoming grid energy supply to match on-site demands. For British factories and manufacturing sites, this is generally a 220V, but the National Grid will typically supply electricity at around 248V. Overvoltage wastes a significant amount of energy, and energy spend, impacting production costs. For a high volume, low margin sector, this can severely impact competitiveness. Overvoltage also puts unnecessary stress on equipment, leading to wear and tear and unnecessary maintenance and downtime. For food and drink manufacturers, precision equipment requires a stable voltage. If this needs to be reset, it can have a major impact on production schedules. While many sites already incorporate VO to
help address these issues, upgrading legacy systems to a modern, dynamic solution can offer additional benefits to help take greater
VO installation
control of energy usage, with real-time voltage management for better performance, reliability and longevity. Traditional VO typically uses a fixed
autotransformer, stepping down the entire supply voltage, incurring copper, core and distribution (I²R) losses that can erode some cost savings and carbon reduction. A modern, dynamic VO offers real-time voltage management, with robust protection for more precise voltage control and improved energy efficiency. Remote monitoring can enable site consumption to be logged, providing plant managers with the performance data to help inform resource efficiency and maintenance scheduling. Reducing Scope 2 emissions with modern
transformers: Many manufacturers include a transformer within their energy management infrastructure, to step-up or step-down voltage. And, where they have invested in on- site renewable assets, a transformer is needed to integrate this sustainable energy, to convert direct current to alternating current. The average age of the UK’s transformer
fleet raises a number of issues for businesses who may have been using them for decades. Whereas we now understand the design lifespan of a transformer to be around 20 years, the 230,000-strong UK fleet has an average age of 60 years. In the worst case scenario, total failure of the transformer, this impacts heavily on production. Unplanned downtime can mean loss of
perishable ingredients and end product, as well as expensive staffing costs. Customer contracts are fiercely competitive and rigidly enforced, and reputational damage along with penalty clauses for non or late delivery can impact contract renewals. Prior to the point of transformer failure, an
outdated unit can be wasting energy, leading to unnecessary costs and emissions. Upgrading to a modern amorphous core transformer
VO FOR SUSTAINABILITY As a leading provider of packaging, turnkey systems and capital equipment into the food industry, Tetra Pak CPS Ltd manufactures cheesemaking equipment for dairy customers worldwide. With a sustainability-focused ethos, they wanted to reduce their environmental impact and energy consumption. A site survey indicated a high incoming
voltage, along with fluctuations which could lead to disruption to production. The installation of voltage optimisation has stabilised voltage, reduced supply by an average of 22.1V, lowering annual energy usage by ten percent. As the company’s Managing Director commented, “Powerstar identified waste that we did not think we had. They diligently overcame issues during commissioning and have provided us with a fault free system that saves what they promised.”
TRANSFORMERS AND VO IN TANDEM, A FOCUS ON ESG As a company with strong sustainability credentials, Quorn Foods is committed to improving production efficiency, driven by their Supply Chain Sustainability Strategy. Following a site survey, Powerstar
recommended replacing existing transformers with modern alternatives with integrated VO. These new assets have reduced Quorn’s energy consumption by around 10 per cent, cutting emissions by 365 tonnes and saving nearly £72,000 in energy spend.
AUTOMATING FOOD AND DRINK PRODUCTION, FOR COMPETITIVENESS AND SUSTAINABILITY Wherever a business sits in the supply chain, increasing efficiency and reducing energy usage is vital. As supermarkets and retailers face consumer and regulatory pressure to publicly report on their Net Zero strategies, manufacturers who are actively reducing their own emissions will have the competitive edge. Although confidence in the food and drink
sector is low, in the current economic climate, the sector’s appetite to invest in automation shows a positive and resilient response. But where this leads to increased energy usage, mitigating costs is critical. Investment in modern energy technologies, in tandem with automation, can offer immediate payback, through reduced consumption, greater efficiency, while furthering decarbonisation ambitions.
Powerstar transformers Powerstar
www.powerstar.com FACTORY&HANDLINGSOLUTIONS | SEPTEMBER 2025 29
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