Reliable Power Transformation for Food Manufacturing

Segment and Application

A global food and beverage manufacturer required a reliable power distribution solution for a high-volume production facility in Mexico. The site supports continuous baking and packaging operations where electrical reliability directly impacts output, product quality, and plant uptime.

The facility operates at approximately 2,300 meters above sea level, creating additional thermal stress on electrical equipment. Production lines run continuously and include modern industrial loads that introduce overload conditions and non-sinusoidal loading. Corporate sustainability objectives also influence equipment selection, with a preference for dry type technology that minimizes environmental and fire risk.

The transformer serves as a primary distribution asset feeding critical manufacturing lines, making reliability and visibility into operating conditions essential.

The Design Challenge

The project began after a dry type transformer at the facility experienced a failure, prompting a review of the site’s power infrastructure and equipment selection strategy. The customer needed a solution that addressed the root cause while improving long-term reliability and aligning with sustainability goals.

Key challenges identified:

• High altitude operation reducing transformer cooling capability and thermal margin
• Continuous production with overload demands and non-sinusoidal industrial loads
• Consideration to replace the failed unit with an oil filled transformer, increasing fire and environmental risk
• Need to align with corporate sustainability and safety objectives
• Limited visibility into operating conditions and early warning indicators

Simply replacing the failed unit without addressing altitude, loading, and monitoring would not resolve the underlying reliability risk. The customer required a solution engineered specifically for the operating environment.

The HPS Solution

HPS approached the project as an engineering-driven design review, evaluating site conditions, loading characteristics, and environmental constraints. The result was a dry type transformer solution designed for high altitude industrial operation with integrated monitoring.

Solution delivered:

• VPI dry type transformer with 220°C insulation system
• Designed and validated for high altitude operation near 2,300 meters
• UL certified design supporting broader acceptance and standardization
• DOE 2016 efficiency compliance supporting energy reduction goals

Electrical performance enhancements:

• Temperature rise design supporting overload capability
• Nonlinear load capability up to K-13
• Improved thermal margin for continuous operation

Digital monitoring capability:

• Integrated IIoT smart power meter for real time visibility
• Remote monitoring of loading and operating trends
• Early detection of abnormal conditions
• Support for predictive maintenance strategies

This approach allowed the customer to maintain dry type technology while improving reliability and gaining operational visibility.

The Results

Commissioning feedback confirmed improved reliability and operational visibility.

Observed results:

• Reliable dry type operation at high altitude
• Improved tolerance to overload and non-sinusoidal loads
• Elimination of oil related fire and environmental risk
• Compliance with energy efficiency objectives
• Real time visibility into transformer operating conditions
• Ability to identify abnormal loading trends before failure

Customer outcome:

The customer restored confidence in dry type technology while improving reliability, safety, and sustainability alignment. The addition of IIoT monitoring enabled a shift from reactive maintenance to proactive asset management. By addressing altitude, loading conditions, efficiency, and monitoring in a single solution, HPS delivered a transformer designed for real operating conditions and long-term performance.