Modernising the Manufacturing Process: Key Considerations for Electrical Upgrades in Manufacturing.
Upgrading electrical systems in the manufacturing plant process isn’t just crucial for enhancing efficiency, ensuring safety, and maintaining competitiveness.
As technology advances and demands for efficiency, safety, and sustainability grow, modernising electrical infrastructure is imperative.
“Actively identifying and implementing opportunities for electrical system upgrades in the manufacturing process can reap real rewards in the long term.”
Joel Randoll, Director
As industrial electrical experts with a wealth of experience in helping manufacturers, we know the complexities involved.
Our customers include those who operate warehouses, industrial factories and production lines, and substantial commercial businesses where electrical systems are both vital and complex.
That all makes upgrading electrical systems in the industrial manufacturing process a critical endeavour that requires careful planning and execution.
In this new insight guide, we take a look at the key elements that must be addressed when undertaking such an upgrade, ensuring a successful transition that enhances productivity and minimises risks.
As technology progresses and production demands evolve, particularly in continuous production environments, the electrical infrastructure must also adapt. Let’s explore the essential considerations for successfully upgrading electrical systems in manufacturing settings, focusing on planning, technology integration, safety standards, energy efficiency, and system reliability.
The cost of not upgrading electrical systems?
That can be influenced by the current high cost of energy, which is significantly impacting industrial and commercial manufacturers, increasing operational expenses and reducing profit margins.
Energy-intensive industries, such as manufacturing, face substantial financial strain as they allocate a larger portion of their budgets to energy costs. This escalation can lead to higher production costs, which may be passed on to consumers through increased product prices, potentially reducing market competitiveness.
Additionally, fluctuating energy prices create financial uncertainty, making it challenging for manufacturers to plan long-term investments and maintain stable operations. Consequently, the high cost of energy compels manufacturers to seek energy-efficient solutions and alternative energy sources to mitigate expenses and protect their bottom line.
Actively identifying and implementing opportunities for electrical system upgrades in the manufacturing process can reap real rewards in the long term.
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How we Simplify Electrical Upgrades, Improve Energy Efficiency & Enhance Industrial Electrical Safety.
Because we service a diverse range of customers across manufacturing, we know how operations differ greatly from business to business. That’s why we take a bespoke approach to every manufacturing plant upgrade project.
However, in every case, our industrial electrical engineers begin the process of upgrading electrical systems with comprehensive planning and assessment phase.
So, what’s important when upgrading electrical systems in the manufacturing process?
Here’s our Top 10
1. Assessing Current Infrastructure
2. Defining Objectives and Requirements
3. Budgeting and Financial Planning
5. Selecting Appropriate Technology
6. Integration with Automation Systems
7. Energy Efficiency and Sustainability
8. System Reliability, Redundancy and Scalability
10. Engaging Qualified Professionals
1. Assessing Current Infrastructure
Before embarking on an upgrade, a comprehensive assessment of the existing electrical infrastructure is essential. The kinds of evaluations we carry out are tailored to our customers’ specific needs and industry regulations but can include:
Condition Analysis to inspect the age, wear, and performance of existing components.
Load Capacity Review to determine if the current system can handle increased loads or if upgrades are necessary.
Compliance Check to ensure the system meets current industry standards and regulations.
Our expert industrial electrical engineers will always put particular focus on identifying inefficiencies or safety hazards, most especially in continuous production lines where downtime can result in significant disruption.
Ensuring compliance with local, national, and international regulations is mandatory.
Our experienced, expert team will ensure you’re covered in terms of:
Safety Standards
Adhering to HSE, BS, and other relevant safety standards.
Environmental Regulations
Meeting DEFRA guidelines for emissions and waste management.
Industry-Specific Standards
ollowing standards specific to the manufacturing sector, such as BSI for fire safety.
It’s important to note the distinction between upgrading electrical systems and assessing your current system. Doing that may require an Electrical Installation Condition Report (EICR) – especially if you need to adhere to specific compliance and regulations. If that sounds like something you need, it’s even more important you get an EICR in a way that is cost-effective, compliant and efficient.
The cost of a commercial EICR Electrical Installation Condition Report
2. Defining Objectives and Requirements
By clearly defining the objectives of the upgrade, we can better align outcomes with organisational goals. We’ll ask about your business strategy and any plans for diversification or growth to ensure our plan for upgrading electrical systems helps you to meet your goals. We’ll cover all these key areas:
Increasing Capacity to build in how we accommodate future expansion plans.
Enhancing Efficiency to help reduce energy consumption and operational costs.
Improving Safety to minimise risks of electrical hazards.
Sustainability Goals to help integrate renewable energy sources and eco-friendly practices.
Understanding your operational goals and needs is particularly important if your manufacturing process relies on the 3 phase power systems that are essential for heavy machinery and large-scale production lines.
3. Budgeting and Financial Planning
Upgrading electrical systems can be costly, so careful budgeting is crucial. We’ll create a plan that addresses all of your priorities in terms of:
Cost Estimation, wherever possible providing a projection of costs for equipment, labour, and contingency.
Return on Investment (ROI) to calculate long-term savings and benefits.
Financing Options, including exploring grants, loans, or incentives available for energy-efficient upgrades.
4. Safety Enhancements
Safety is paramount and most often a key driver of manufacturing plant upgrades. Even where safety is not the first priority, we aim to ensure that upgraded electrical systems enhance overall safety.
We look at considerations that include:
Arc Flash Protection, implementing measures to protect against arc flash incidents.
Grounding and Bonding, ensuring proper grounding and bonding to prevent electrical shocks.
Emergency Response, establishing protocols for quick response to electrical emergencies.
If safety is a key area for you – and particularly if your manufacturing facility employs 3 phase power systems, we will also look at:
Up-to-Date Protection Devices
We can install modern circuit protection devices that address the complexities of 3 phase electric systems, which are prone to unique issues such as phase imbalance or harmonic distortion.
Emergency and Backup Systems
We can ensure reliable emergency systems are in place. This is critical for continuous production lines where even short interruptions can cause significant operational disruptions.
Regular Maintenance Schedules
Ask us about setting up routine maintenance for 3 phase power systems to prevent failures and ensure ongoing compliance and safety.
5. Selecting Appropriate Technology
Choosing the right technology is pivotal to the success of the upgrade. This can involve:
Exploring the latest innovations and how they might integrate with your manufacturing process.
Assessing compatibility to ensure new components are compatible with existing systems.
Assessing scalability to ensure we select systems that can be easily expanded or upgraded in the future.
Integrating advanced technologies is a key element of upgrading electrical systems and our team are experts in all.
6. Integration with Automation Systems
Modern manufacturing heavily relies on automation. Upgrading electrical systems should align with automation goals, including:
Compatibility with PLCs and SCADA to ensure new systems integrate seamlessly with existing automation controls.
Smart Technologies, for example IoT devices and smart sensors, that can be incorporated to enhance control and monitoring.
Future-Proofing by designing systems that can adapt to future technological advancements.
7. Energy Efficiency and Sustainability
In addition to incorporating more appropriate or innovative technology, modernising electrical systems with a focus on energy efficiency and sustainability can yield significant benefits.
Key areas for us include:
Energy Audits to identify areas for improvement.
Energy-Efficient Equipment such as high-efficiency motors, transformers, and lighting.
Renewable Energy Integration that can include solar, wind or other renewable energy sources.
While energy efficiency matters everywhere, it is most critical in continuous production settings that consume significant power.
We can advise on:
Energy-Efficient Lighting
Although a small part of the total energy use, switching to LED lighting contributes to overall efficiency improvements in manufacturing processes.
High-Efficiency Motors and Drives
You can significantly reduce energy consumption by replacing older motors and drives used in the line of production with high-efficiency models suitable for 3 phase power.
Energy Management Systems
Ask us about implementing systems to monitor and optimise energy use. This is particularly effective in plants with three-phase electric setups due to their complex load distributions.
You might also be interested in:
Smart Grids & Metering
Smart grids can seriously improve your energy management – which is really important in plants with continuous production cycles that demand constant, reliable power.
Automation and Control Systems
Can help you to be more efficient and effective with labour, freeing staff up by automating processes and enhancing control systems such as PLCs and SCADA.
Renewable Energy Sources
Modern technology is now more than capable of supplementing the 3 phase electric supply. Incorporating renewable energy sources reduces reliance on non-renewable sources and enhances your sustainability credentials.
If you’re thinking about the potential Solar PV could offer your business – and your bottom line – ask us! We’re also expert in Solar installation and maintenance.
8. System Reliability, Redundancy and Scalability
Reliability is critical in industrial manufacturing to avoid costly downtimes. Key strategies include:
Redundant Systems should be identified and backup power supplies implemented.
Regular Maintenance is essential – we can help by establishing a maintenance schedule to ensure ongoing reliability.
Monitoring Systems that utilise real-time monitoring and diagnostic tools to detect issues early.
Because the reliability of an electrical system is crucial, especially for plants operating under continuous production regimes, we build-in both system reliability and scalability through:
Reliability Analysis
Including redundancy and fail-safes in 3 phase electric systems to ensure continuous operation, critical for continuous production lines.
Scalable Design
Wherever possible, we create systems with the flexibility to expand, allowing for easy integration of new machinery or processes that may need additional 3 phase power capabilities.
Advanced Diagnostics and Monitoring
Employing tools that monitor three-phase electric systems to predict and pre-emptively address potential failures, essential for maintaining the integrity of continuous production lines.
9. Minimising Downtime
Because we understand the need to maintain productivity, we take a careful, flexible approach to minimising production downtime during the upgrade process.
We can plan an approach that suits your operations, which may include:
Phased Implementation, planning the upgrade in phases to reduce disruptions.
After-Hours Work, including scheduling work during non-peak hours or shutdown periods.
Temporary Power Solutions that ensure critical operations continue to run reliably.
10. Engaging Qualified Professionals
The expertise of qualified professionals is indispensable for a successful upgrade. This includes:
Experienced Industrial Electrical Engineers who can plan, design and oversee the upgrade.
Certified Electricians who can sign off safe and compliant installation.
Project Managers who can co-ordinate the various aspects of the upgrade, minimising downtime and maximising potential at every step.
Our team are qualified and expert, skilled & experienced.
If you’re still not sure where to start – just ask us! Upgrading electrical systems in the industrial manufacturing process is a complicated endeavour that is best left to the experts.
From assessing the current infrastructure to selecting appropriate technology and ensuring compliance with regulations, each step plays a crucial role in the success of the upgrade.
By focusing on energy efficiency, safety, reliability, and continuous improvement, manufacturers can enhance productivity, reduce costs, and achieve long-term sustainability.
Proper planning, execution, and ongoing management are all essential to realising the full benefits of a modernised electrical system.
You might also be interested in Optimising Operations: Machinery Maintenance & Repair Strategies for Industrial Electrical Equipment.
