We work with many clients across many different industries. See our most recent case studies below to explore the benefits of Powerstar.

Cutting & Wear Resistant Developments Ltd

The client

Cutting & Wear Resistant Developments started in 1968 manufacturing hardfacing materials for the oil and gas drilling industry. They have since diversified and alongside developing its hardface technology they now also manufacture downhole tools.

The brief

Cutting & Wear were looking to reduce their energy consumption at their 38,000 sq ft manufacturing facility based in Sheffield.

As a company they look to minimise their effect on the environment by reducing & recycling waste, controlling emissions and preventing pollution.

The project

Through a site evaluation, voltage profile measurement and analysis of the sites electrical characteristics, the Powerstar team recommended replacing the current HV distribution transformer with a 800kVA Powerstar HV MAX – a super low-loss amorphous core transformer, with electronic dynamic voltage optimisation.

The results

Replacing the current transformer with the amorphous core Powerstar HV MAX has significantly reduced transformer losses (both iron and copper losses), providing the site with a more efficient and cost effective transformer. The electronic-dynamic optimisation from Powerstar ensures significant savings can be made in addition to those from upgrading the transformer through optimising, cleaning and conditioning the incoming power supply.

The transformers used in the Powerstar HV MAX systems already surpass the 2021 EU Ecodesign Directive standards set by European Commission, providing a high efficient solution which provides greater returns on investment over the transformers lifespan in comparison to conventional low-loss transformers.

Bromsgrove Winding Services

Key Points

  • Energy consumption savings: 9.5%
  • Annual kWh saving: 107,659
  • Tonnes of CO2 saved: 58.7 tCO2
Holmfirth Dyers Limited

The client

Established in 1985 as Commission Dyers and Finishers, Holmfirth Dyers work closely with Designers, Dying and Finishing fabric for the Fashion and Upholstery Industries. The business is family run, processing in excess of 6.3 million metres of fabric per annum in a plant renowned for its investment in cutting edge technology and service driven delivery to their valued customers.

The brief

The company were looking to reduce their energy costs and energy consumption at their works in Holmfirth, becoming more environmentally friendly in the process. Machinery which is key to the companies operations, could not be affected by any potential energy saving solutions to be installed on site.

The project

Powerstar completed a full site survey and found that there could be a significant reduction in energy savings, particularly on the Process Heating and Motors with variable speed drives. The full site survey also shown that replacing the existing, inefficient transformer, would provide further savings.

A Powerstar HV MAX 1000kVA system was installed replacing the existing transformer on site. The HV MAX unit regulated voltage output with its super low-loss amorphous core reducing energy consumption on the site by 10.9% conventional low-loss transformers.

The results

Equipment on site now has reduced maintenance costs and increased lifespan thanks to the new, corrected voltage level. The HMI (Human Machine Interface) allows for savings data to be monitored at the unit or via a desktop application.

Customer quotation

“The Powerstar system has allowed us to make energy savings, reduce our carbon footprint and at the same time replace our transformer. We are very pleased with the HV MAX system and the level of service provided.”

Geoff Goodman, Financial Controller, Holmfirth Dyers

Bromsgrove Winding Services

Key Points

  • Energy consumption savings: 10.9%
  • Annual financial savings: £13,852
  • Tonnes of CO2 saved: 58.7 tCO2
Patrington Haven Leisure Park

The client

Patrington Haven Leisure Park is an award winning 5 star caravan park based in the East Riding of Yorkshire. Set in 40 acres of beautiful countryside close to many award winning beaches the park boasts numerous facilities including a fishing lake, bar, restaurant, heated indoor swimming pool, fitness centre and a multi –sports court.

The brief

The park is very keen on protecting the environment, as evidenced by the David Bellamy Gold Conservation award for the work they have done to protect and enhance the landscape around them, and were looking at ways to reduce their carbon footprint and save energy.

After consultations with PJD Electrical & Solar, the management team at the park decided to ask Powerstar to survey the site and recommend a solution.

The project

The Powerstar team recommended that the park should replace their 1965 HV distribution transformer with the Powerstar HV MAX distribution transformer with integrated electronic voltage optimisation. Powerstar HV MAX solutions exceed the Eco Design 2021 efficiency specifications, providing a solution which provides greater returns on investment over the transformers lifespan.

The results

Powerstar HV MAX provided the park with more than just an energy efficient transformer to replace their older model.

Replacing the old HV distribution transformer with a low loss amorphous core transformer delivered a more energy efficient electricity supply.

The integrated electronic voltage optimisation provides additional benefits of a stabilised, constant voltage output and further savings in electricity consumption.

Bromsgrove Winding Services

Key Points

  • Consumption savings: 16.9%
  • Tonnes of CO2 saved: 144.2 tCO2
  • Annual financial Savings: £23,233
System 3 Ltd

The client

System 3 Ltd is recognised as one of the UK’s leading manufacturers of high specification double-glazed units for both domestic and commercial applications.

The brief

The company were looking to upgrade their HV infrastructure by replacing two existing HV transformers on site (TX2 & TX3).

As a site with an annual load of close to 6,000,000 kWh System 3 Ltd were also looking for ways to reduce overall annual electricity usage.

As a company with a reputation for excellence at all levels from initial design, through to manufacture and delivery it was essential that any technologies implemented could be integrated without negatively impacting on business operations.

The project

Powerstar HV MAX was identified as an ideal solution for System 3 Ltd, providing a combined solution to the two problems faced.

Firstly, it will allow the company to upgrade their HV infrastructure; replacing the inefficient, conventional transformers with a super-low loss amorphous core models.

This upgrade will significantly reduce transformer losses (both iron and copper losses), providing the site with a more efficient and cost effective transformer.

Secondly, the integrated electronic-dynamic voltage optimisation technology from Powerstar will ensure that significant electricity consumption savings are made in addition to those from upgrading the transformer through optimising, cleaning and conditioning the incoming power supply.

The Powerstar team offered a full concept to completion, turnkey solution and remained flexible and proactive throughout to ensure the project was implemented with no disruption to System 3 Ltd’s business operations.

The results

Following the installation of Powerstar HV MAX,
System 3 Ltd are set to benefit from overall energy savings of 10.9%, equating to an annual reduction of 640,511kWh.

Along with significant reductions in energy consumption and increase in efficiencies of the HV infrastructure System 3 will benefit from reductions in carbon emissions of over 300 tonnes and significant financial savings of almost £60,000 per year.

Bromsgrove Winding Services

Key Points

  •  Actual Annual Consumption Saving: 10.9%
    •  TX2 Savings (40% of site consumption): 7%
    •  TX3 Savings (28% of site consumption): 10,9%
  • Annual kWh Savings: 640,511 kWh
  •  Tonnes of CO2 Saved: 317.92 tCO2
  •  Annual Financial Savings: £59,055
Paragon Quality Foods Ltd

The client

Paragon Quality Foods Ltd is one of the largest suppliers of quality burgers and doner kebabs to the food service and fast food sectors in the UK.
The factory, based in Doncaster, is one of the most modern and technologically equipped of its kind in Europe.

The brief

With production taking place all 52 weeks of the year and an annual load of over 3,700,000 kWh, Paragon Quality Foods Ltd were keen to better their energy management and reduce overall electricity usage.

With lean manufacturing and efficiency at the heart of their operations, to ensure the most competitive prices to their customers, they were looking for ways to improve their processes further to yield both a financial and environmental benefit.

As a company with a reputation for excellence, it was essential that any technologies implemented could be integrated without negatively impacting on business operations.

The project

As Paragon Quality Foods Ltd owned their onsite transformer, Powerstar HV MAX was identified as a viable solution. The upgrade replaced any existing conventional transformers with a super-low loss amorphous core model, reducing transformer loss from the outset.

Secondly, the integrated electronic-dynamic voltage optimisation technology from Powerstar MAX will ensure significant savings to electricity consumption. This is achieved through optimising, cleaning, and conditioning the incoming power supply, which was recorded as high as 243.6V.

The Powerstar team delivered a concept to completion solution and remained flexible throughout the ensure no disruption was made to Paragon Quality Foods Ltd’s business operations.

The results

Following the installation of Powerstar HV MAX, Paragon Quality Foods Ltd have exceeded their guaranteed energy saving and benefit from an overall energy saving of 12.3%, equating to an annual reduction of 462,882 kWh.

Bromsgrove Winding Services

Key Points

  • Annual consumption saving: 12.3%
  • Annual CO2 savings: 206.73 tonnes
  • Annual kWh saving: 462,883 kWh
  • Annual financial saving: £38,975
  • Voltage reduction: 15.5V
  • Payback period: 3 years 3 months
HV upgrade for a UK glass manufacturer

The client

The client manufactures high specification insulating glass sealed units and toughened-laminated glass.

The UK based company has a stringent commitment to quality at all levels from initial design through to manufacture and delivery.

The brief

The company was looking to upgrade their HV infrastructure by replacing two existing HV transformers on site (TX2 & TX3). As a site with an annual load of close to 6,000,000 kWh they were also looking for ways to reduce overall annual electricity usage.

As a company with a reputation for excellence at all levels, from initial design through to manufacture and delivery, it was essential that any technologies implemented could be integrated without negatively impacting on business operations.

The project

The Powerstar super low loss amorphous core transformer with integrated voltage optimisation technology was identified to solve the client’s problem as it provided a combined solution to the two problems faced.

Firstly, it allowed the company to upgrade its HV infrastructure; replacing the inefficient, conventional transformers with super low loss amorphous core models which significantly reduced transformer losses (both iron and copper losses), providing the site with a more efficient and cost-effective transformer.

Secondly, the integrated electronic-dynamic voltage optimisation technology ensured that significant electricity consumption savings were made in addition to those from upgrading the transformer through optimising, cleaning and conditioning the incoming power supply.

The concept to completion, turnkey solution was installed with a flexible and proactive approach to ensure minimal disruption was caused to the client’s business operations.

The results

Following the installation, the company benefits from overall energy savings of 10.9%, equating to an annual reduction of 640,511kWh.

Along with significant reductions in energy consumption and increases in efficiencies of the HV infrastructure, they will benefit from reductions in carbon emissions of over 300 tonnes and significant financial savings of almost £60,000 per year.

Bromsgrove Winding Services

Key points

Actual annual consumption savings: 10.9%

  • TX2 savings (40% of site consumption): 7%
  • TX3 savings (28% of site consumption): 10.9%

Annual kWh saving: 640,511 kWh

Tonnes of CO2 saved: 317.92

Annual financial savings: £59,055

Engineering a bespoke solution in the Lowlands

The client

A client based in the Central Lowlands of Scotland, part of a large international engineering group, recently required a bespoke engineered solution following the breakdown of the site’s transformer.

The client is the UK’s largest dedicated engineering service hub with a 75,000 square feet site housing dedicated servicing capabilities for valve, pump and renewable customers.

From this location, the client specialises in providing a manufacturing, sales, and service hub for engineering services across the UK.

The brief

Due to the size and demand of the site, the client relies on its transformer to keep the facility and its operations running on schedule. So, when the site’s high voltage (HV) transformer broke down, it was imperative that it be made functional again as soon as possible.

Refurbishing and rewinding of the transformer was required with a very tight turn-around time of no more than 6 weeks, as the client had several pumps that required testing before being dispatched to the North Sea.

The project

The issue was identified quickly and the process of rewinding the transformer to a bespoke design, as required by the client’s needs, began.

The new transformer was successfully installed within the strict required timeframe, with minimal disruption caused to the site’s daily operations, allowing enough time for the client to honour its commitments to its own clients.

The 2000kVA, 6000V transformer is an incredibly complex transformer due to the extremely wide voltage tap range that was ultimately required to give the customer the flexibility while testing their pumps.

The results

Rewinding such a large bespoke unit to such a short deadline was an exciting challenge that was met with great enthusiasm by the engineers.

Following the projects successful implementation within the required timeframe, a spokesperson for the client expressed their contentment with both the price and fast delivery time of the installation. They went on to comment that they greatly appreciated the weekly updates and full-service solution provided by the dedicated team of engineers.

Bromsgrove Winding Services

“We have been very pleased with the quality and workmanship from the team at Powerstar – the energy savings have been higher than forecast and we are expecting to run a phase 2.

Powerstar has been very flexible in scoping, design and working around our operational units to ensure full services were maintained. I have no hesitation in recommending Voltage Optimisation from Powerstar and we are pleased with the full service Powerstar provided.”

Stuart Harris, Head of Energy and Carbon Operations | BT Technology, Service & Operations

“We trusted Powerstar technology for our company to save money and energy while reducing the carbon footprint. Saving results proved that we have made the correct decision. Powerstar technology is highly recommended to any interested party.”

Harris Kakoulli, Board Member | KPMG

“RACC is a large academic institution comprising 3 large buildings. We decided to spend the grant money on installing energy efficient gas boilers and voltage optimisation units.

We had a Powerstar 210kVA unit installed at two of our sites. On average reducing the voltage by 5% will result in a saving of 10%. We were told by specialists that the installation of the Voltage Optimisation units will mean a saving of 14-19% and 12-16% respectively for the two of our sites.”

Spokesperson | Richmond Adult Community College (RACC)

“Powerstar voltage optimisation has been a major part of our comprehensive energy efficiency programme. It is perhaps the simplest and most effective way to instantly save energy and therefore we would highly recommend Powerstar systems.”

Mark Orpin, Head of Energy Management | ASDA Supermarkets

“Having the Powerstar unit installed and working in less than 4 weeks from order did indeed impress us but saving £2,000 a month on our electricity bill was even more impressive.”

Graham Hall | Oxley Threads

“The installation of Powerstar has cut our energy cost by nearly 20%. This is another positive step in TEV’s continuing commitment to the ISO14001 accreditation.”

Chris Chisman, Engineering Manager | TEV Ltd

“As part of our efforts to achieve the highest efficiency rating for our buildings, Powerstar has been installed to three leisure centres within the council. The results have been exciting with an average of 12.5% reduction in the three leisure centres. As a direct result of the Powerstar installation and other efficiency measures, our efficiency ratings were excellent.”

Martin Perrow, Energy Manager | Restormel Borough Council

“It was fantastic that we were able to purchase from a local business. It was great to receive the loan from the Carbon Trust, but more importantly, this does appear to be an extremely elegant solution to reducing energy consumption, with no adverse impact and indeed a potential positive benefit to equipment life.”

Chris Rea, Managing Director | AESSEAL

“The purpose of this project was to reduce our energy consumption at the National Metal Forming Centre. This has been achieved with the installation of the Powerstar which has cut our energy costs by 21%.”

Dr Alan Arthur, Centre & Events Manager | National Metal Forming Centre

“The installation of the Powerstar systems has cut our energy cost by nearly 18%. This is a fundamental step towards our efforts to minimise our carbon footprint.”

Phil Mason, Facilities Manager | ISG Totty

“By quickly identifying the waste and developing the specific solution for our company, the Powerstar team has helped us to reduce our impact on the environment and substantially lower our electricity bills.”

John Whitesmith, Manufacturing Director | Polyflor PLC

“The voltage optimisation system is a great example of a change that we can make which helps the environment and saves money without any effect on the services we provide.

By making this change, we can reduce the amount of energy we use in the building, yet still operate all of the same technology and systems that we currently use”.

Councillor Allan Holliday, Portfolio Holder for the Environment and Sustainability | Copeland

“We are more than happy and pleased we made this investment. We are also glad we are making a contribution in the responsible use of Palais Hotel power. You can see the Powerstar system is built with long-life materials, so are happy with the quality of the unit. I have seen enough evidence to know that this is wise investment that we expect to pay for itself within three years.”

Bob Karpluk, General Manager | Palais Hotel

We are extremely pleased with the outcome and very glad that we have made the investment. Well done and thanks again

Matthew von Brockdorff | Atlas Insurance

“The operational aspect of the units has been 100% reliable – We have been very pleased with both the units and service provided by Powerstar”

Paul Spence,  Finance Director | W Brewin Ltd

“The team worked out of hours to install the Powerstar Voltage Optimisation unit. It was a straight forward process with good energy saving results. I would recommend EMS to other organisations looking to save energy.”

Chris Porter, Facility Manager | Tadcaster Swimming Pool

“Powerstar voltage optimisation has been a major part of our comprehensive energy efficiency programme. It is perhaps the simplest and most effective way to instantly save energy and therefore we would highly recommend Powerstar systems.”

Mark Orpin, Head of Energy Management | ASDA Supermarkets

“We are absolutely delighted with the Powerstar system which has reduced our direct electricity and carbon emissions by 16%. I have no hesitation to recommend Powerstar to others.”

Stephen Ward, Senior Electrical and Mechanical Engineer | Sheffield Hallam University

“We have experienced no issues or problems with the Powerstar equipment we have had fitted for the past year. The kit is robustly manufactured and electrically sound.”

Peter Gardiner, M&E Manager | Lincolnshire Co-operative

“A year after the installation of Powerstar unit at our premises and upon reviewing the significant saving results in electricity consumption we decided to install a second system.”

Marios Sarris, Electrical Engineer & Automations Manager | Photiades Breweries

“We would highly recommend Powerstar voltage optimisation systems. The Powerstar installation at Scott Clinic, Mersey Care NHS Trust has achieved an 18% saving on total electricity consumption. This is an excellent result which is helping the hospital to meet its CO2 reduction targets. Powerstar voltage optimisation has shown that significant savings can be achieved without compromising the operations of the hospital.”

Mark O’Grady, Managing Director | MITIE Engineering (North) Ltd

“We are highly delighted with the service provided from Powerstar and the great savings we have received with such a low payback period.”

Jason Dalgarno, Maintenance Manager | No Ten Manchester Street Hotel

“We have been greatly impressed by the outcome of the installation and have seen an immediate saving in our power consumption and stability of supply.”

Mark Betteridge, Club Manager | Bristol & Clifton Golf Club

“Powerstar (Cyprus) worked with a high level of professionalism to ensure that during the installation of Powerstar and the verification process, the operation of the university wouldn’t be interrupted. The saving results have exceeded the guaranteed savings therefore the payback period will be reduced.”

Michalis Mavros, Health and Safety officer | European University, Cyprus

“As elected officials we are always researching opportunities that will reduce our dependence on consumable resources. This creates a win-win as we are not competing with our citizens and local industries for these finite resources. We chose to install Powerstar due to its scalability and the impressive reduction in kWh it provided. The 100% guarantee of savings made it a zero risk solution.”

Mr Don Briggs, Mayor | The town of Emmitsburg, Maryland, USA

“Many thanks to Powerstar for a professional service provided. I can highly recommend voltage optimisation as an energy saving & power quality solution to the education sector.”

Mr Alan Greensitt, Director of Finance & Resources | St John’s School & Sixth Form College

“We are constantly looking to minimise our impact on the environment and when we were presented with Powerstar it gave us an effective, guaranteed option to reduce our electricity consumption and carbon emissions. Along with the positive environmental impacts we have seen a reduction in motor drive failures, giving us greater efficiency and providing further savings on top of those promised.”

Dave Burrows, Plant Provision Manager | Newburgh Precision

“As part of our sustainability programme we targeted electricity supply as an area where efficiencies could be saved and cost savings made. The aim of installing the voltage optimiser was to save money and energy whilst boosting efficiency. I have no hesitation in recommending Powerstar and their products to any interested party.”

Representative | King Edward VI College

“With continual monitoring we expect to see savings in excess of 6% guarantee – a great level of return on investment. We are now able to produce up to 50 tons more product with the same kWh usage and are well on track to achieve payback in 20 months which is quite phenomenal. Importantly by reducing energy consumption, Powerstar is also helping PALRAM’s commitment to conserve the environment.”

Matthew Healey, Technical Manager | PALRAM Polycarb

“We have seen a reduction of 16.3% in our total electricity consumption since the installation of the Powerstar system. Our maximum demand has also dropped by 21% which is an additional saving in costs, we never calculated in the first place, hence further improving our payback. Powerstar was impressive in all aspects from initial meeting to final installation.”

Adam Mansell | British Apparel Textile Confederation

“We have always strived to minimise the use of electricity and gas at our company, however most of our efforts related to non-productive items, such as lighting and heating. The installation of the Powerstar system has reduced our total electricity consumption by almost a quarter (23%) and we are absolutely delighted.”

Quentin Mackenzie, Managing Director | Purification Products

“Powerstar are a unique find. They provide simple, pragmatic solutions to reduce energy consumption. Benefits are instant and Powerstar’s confidence in the product is reinforced by guaranteeing the promised savings. If you are serious about energy reduction, we certainly advocate the effectiveness of energy optimisation equipment.”

James Bowyer, Quality Manager | Birmingham Stopper

“We are committed to reducing our energy consumption and CO2 emissions throughout the district. This decision highlights our dedication to reducing our own carbon footprint. The projected savings that Powerstar is set to deliver will be a welcome boost towards helping us achieve our energy efficiency targets. It was also ideal to be able to purchase from a local company.”

Dennis Kelly, Cabinet Member for the Environment | Bolsover Council

“Powerstar has been the best investment we have made to reduce our electricity costs and make ongoing savings in the future, at a time when energy prices continue to rise. The team at Powerstar are exceptional professionals and we would recommend their expertise and the Powerstar product to anyone one who wants to see genuine reductions in their electricity consumption and carbon emissions.”

Quentin Colley, Vice Principal | Portland College

“We were promised 6.8% minimum savings on the Main LV Panel and based on the two weeks comparison, the LV panel has shown an 8.7% reduction in consumption. Just to add that we will keep monitoring the LV panel consumption for a longer period (6 months or 1 year), in order to identify the exact percentage of saving achieved.”

Ian Brogaard, Engineering & Safety Manager | Tencate Grass Middle East

“A 13% reduction in our total electricity consumption, based on our suppliers data is an excellent result, which will allow us to not only reduce our energy costs but also meet our CCL targets.”

John Flemming, Director | Stork Brothers Ltd

“We saw voltage optimisation as a major step in our continual need for improvement on our environmental performance. We are very pleased with this energy reduction, which not only help our targets, but has a significant impact on our costs too.”

Colin Hodgson, Operations Director | Charles F Stead

“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.”

Mark Boxall, Managing Director | Tetra Pak CPS Ltd

“We had an excellent experience working with Powerstar USA. Their straightforward process of identifying the potential savings opportunity through the site audit and installation along with their GUARANTEE allowed us to make an easy decision in selecting the HV MAX installation. Savings were higher than expected representing close to 600,000 kWh from one sub-station and we fully expect to continue with additional installations at our facility in the coming years.”

Kevin Kemp, Facilities Manager | Abbott, Case Grand AZ

“In addition to the energy savings we emphasize that both the operational and the installation did not interfere with our manufacturing process. It was simple and efficient.”

Benigno Pereira, General Manager | Queizuar, S.L.

“We found working with Powerstar to be very easy as they did everything they could to accommodate our requirements not only in which unit was best suited to deliver the greatest efficiency, but also in ensuring minimum disruption. Work was carried out overnight which meant that there was no disruption to our operational hours and our customers. This is one of the simplest ways to achieve instant cost effective energy savings and would highly recommend Powerstar.”

Dennis Smith, Project Manager | Tees Active Ltd

“Voltage Optimisation is a fit and forget technology that has been saving us energy since the day it was installed.”

Chris Jones, Sustainability Manager | University of Bristol

“Powerstar delivered a professional service from start to finish in a suitable timeframe, and we are extremely happy with the results of the voltage optimisation solution.”

Phil Drape, Operations Manager | Jesmond Pool

“After thorough investigation, and in close co-operation with our IPMVP company, the anticipated savings convinced us to install the first Powerstar units. The results of the first installations were so convincing, that we chose to install a Powerstar unit in our newly built supermarket.”

Albert Heijn | Hans Geveling BV

“Powerstar has provided us with great savings on our electricity bills with a quick installation and excellent service throughout. We are extremely happy and would thoroughly recommend installing Powerstar voltage optimisation.”

Max Bytheway, Chief Engineer | Portola Packaging Ltd

“We have been looking at ways of lowering our energy consumption and reducing our carbon emissions. Powerstar voltage optimisation offers a great solution and we are achieving higher than expected savings.”

Nabiel Khan, F.C.A Financial Director | Bridgewood UK

“The Powerstar system has allowed us to make energy savings, reduce our carbon footprint and at the same time replace our transformer. We are very pleased with the HV MAX system and the level of service provided.”

Geoff Goodman, Financial Controller | Holmfirth Dyers
Powerstar is a registered trademark of EMSc (UK) Ltd. Company reg no: 4209907. Registered in England and Wales
Copyright © 2018 Powerstar | All rights reserved | Privacy policy | Terms & Conditions | Cookie Policy

Cookies

This website uses cookies. You can read more information about why we do this, and what they are used for Privacy Policy.

Accept Decline