Stop Throwing Money Away: 5 Hidden Costs of Poor Power Quality in Manufacturing

In today’s competitive manufacturing landscape, every penny counts. Businesses are constantly looking for ways to streamline processes, reduce waste, and maximise efficiency. However, many manufacturers overlook a significant hidden cost factor: poor power quality.

While voltage fluctuations, power surges, and harmonics might seem like minor inconveniences, they can wreak havoc on your equipment, production processes, and ultimately, your bottom line. Here are 5 hidden costs of poor power quality that manufacturers need to be aware of:

1. Increased Downtime and Production Loss: Power surges and outages can cause equipment malfunctions and production stoppages. Even minor voltage fluctuations can lead to unstable performance, reducing product quality and increasing the risk of rejects.

2. Higher Maintenance Costs: Poor power quality stresses electrical components, leading to premature wear and tear. This translates to more frequent maintenance needs and higher repair costs.

3. Reduced Equipment Lifespan: Constant exposure to voltage fluctuations and power surges shortens the lifespan of your valuable machinery. This translates to earlier equipment replacements, impacting capital expenditure budgets.

4. Energy Inefficiency: Inconsistent power supply can cause inefficient operation of motors and other equipment. This leads to increased energy consumption and higher electricity bills.

5. Safety Hazards: Electrical faults caused by poor power quality can pose safety risks for your employees. Arcing, overheating, and equipment malfunctions can all lead to potential injuries.

Combating the Hidden Costs: The Power of Industrial Power Control

Fortunately, these hidden costs can be significantly mitigated by investing in a robust industrial power control solution. United Automation offers a wide range of products designed to optimise power quality in manufacturing environments. These include:

• Thyristor Controllers: Provide precise temperature control for heating elements and other industrial processes.
• Soft Starters: Reduce the inrush current during motor startup, minimising wear and tear on equipment.
• AC Voltage Regulators: Ensure consistent voltage supply for sensitive equipment, preventing malfunctions and improving product quality.
• Power Line Filters (EMI Filters): Eliminate electromagnetic interference that can disrupt electronic controls and communication systems.

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Phase Angle Triac Firing Circuit – PATFC

£21.50 ex. VAT

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Compact Power Regulator Chip – CSR / 604 / 1004 / 1504

£25.00 – £30.50 ex. VAT

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AVR – 25A Phase Angle AC Regulator

£90.00 – £91.80 ex. VAT

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CSR power regulators (CSR1, CSR2-B, E Series)

£34.00 – £50.85 ex. VAT

Investing in industrial power control solutions offers a strong ROI for manufacturers. By ensuring clean, consistent power, you can experience numerous benefits:

• Reduced downtime and production losses
• Lower maintenance costs
• Extended equipment lifespan
• Improved energy efficiency
• Enhanced safety for your workforce

Don’t Let Poor Power Quality Drain Your Profits

Don’t let hidden costs from poor power quality erode your manufacturing profits. By taking a proactive approach and implementing industrial power control solutions from United Automation, you can ensure optimal power quality, improve efficiency, and maximise your return on investment.

Contact United Automation today to discuss your specific power control needs and learn how our products can help you achieve a competitive edge.