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Case Study: Enhancing Power Reliability Through Main Switch and Transformer Upgrade for Manufacturing Facility

Overview 

A manufacturing facility in Victoria faced frequent power interruptions, causing production delays, increased downtime, and financial losses. To mitigate these issues, the company decided to upgrade its power transformer and main switch to support a generator backup system.

 Additionally, the upgrade was undertaken to increase the size of the power supply, allowing for the addition of more production machinery in the facility. As the trusted industrial electrical contractors in Melbourne, Aus-Tech was tasked with the upgrades, from sourcing the right product to installation and testing.

This case study explores our work with the client, as well as the benefits achieved through investing in said electrical system upgrades. 

Challenge 
The facility relied on an outdated power transformer and main switchgear that lacked the capacity to integrate a generator backup system. This led to:

Unplanned shutdowns due to grid failures

High restart times affecting production efficiency

Potential damage to sensitive equipment

Increased maintenance costs due to power surges and instability

Our Solution
With Aus-Tech expert advice and knowledge in electrical solutions, we guided the company in implementing the following upgrades:

Transformer Upgrade: Replaced the existing transformer with a higher-capacity, energy-efficient model capable of handling peak loads more efficiently.

Main Switch Upgrade: Installed an advanced automatic transfer switch (ATS) to seamlessly switch between grid power and generator supply during outages.

Generator Integration: Connected a high-capacity backup generator to ensure uninterrupted power supply during grid failures.

Results and Benefits
The electrical upgrades delivered by the Aus-Tech team showed significant improvements to the manufacturing facility, including:

Reduced Downtime: The ATS enabled automatic switchover to generator power in the event of a power outage, minimising production interruptions.

Improved Equipment Protection: A stable power supply prevented voltage fluctuations, reducing wear and tear on machinery.

Better Operational Efficiency: Employees could continue working without disruption, improving productivity.

Cost Savings: Maintenance and repair costs were lowered due to consistent power quality and reduced losses from downtime.

Scalability for Future Growth: The upgraded transformer and main switch supports future expansion without requiring additional major electrical upgrades.

Conclusion

The power transformer and main switch upgrade to accommodate generator backup proved to be a vital investment for the manufacturing facility. Aus-Tech’s expertise and product knowledge ensure that the facility now enjoys enhanced power reliability, reduced operational risks, and long-term cost savings.

 Businesses operating in power-sensitive environments should consider similar upgrades to secure uninterrupted operations and sustainable growth. To learn more about our main switch and transformer upgrades, or any other electrical improvement solutions, contact Aus-Tech’s electrical contractors.