The District Dairy Cooperative in Piątnica is one of the leading dairy product manufacturers in Poland, recognized for its high-quality products and innovative approach to technological processes. However, the intensive operation of production lines, as well as modern drive and control systems, contributed to increasing power quality issues within the facility.
To address the challenges related to high harmonic levels, voltage fluctuations, and rising operating costs, the District Dairy Cooperative in Piątnica partnered with ANIRO. The implemented solution, based on ADF P300 active harmonic filters, significantly improved the stability and efficiency of production processes while optimizing energy-related operating costs.
The following issues were identified at OSM Piątnica:
Elevated harmonic levels – generated by numerous variable frequency drives and other nonlinear loads. Network overloads and overheating of installation components posed a real threat to production continuity.
Voltage fluctuations (flicker) – frequent load changes contributed to power supply instability, which could result in reduced product quality and unplanned downtime.
The need to reduce energy costs – mainly resulting from insufficient reactive power compensation and additional losses caused by the flow of higher-order harmonics.
Due to the growing scale of production and the necessity to ensure uninterrupted operation of technological lines, finding a durable and effective solution became a priority for OSM Piątnica.
Solution
ANIRO experts conducted detailed measurements and an analysis of the electrical power system within the facility. Based on the collected data, a modernization concept was developed using ADF P300 active harmonic filters in the following configuration:
Three ADF P300-450A units
Two ADF P300-375A units
Two ADF P300-250A units
Main objectives of the implementation:
Harmonic reduction
The ADF P300 active filters rapidly eliminate a wide range of harmonics, focusing primarily on the lower-order harmonics that place the greatest burden on the power network.
Dynamic reactive power compensation
The devices provide continuous and smooth compensation, resulting in reduced energy costs, lower risk of penalties for exceeding permissible parameters, and improved energy balance.
Voltage stabilization
By reducing voltage fluctuations (flicker), machine operating conditions were improved, increasing process safety and reducing the number of failures.
Flexibility and expandability
The modular architecture of the ADF P300 system enables future expansion of compensation capacity if further development of the machinery infrastructure becomes necessary.
Results
- The implementation of active harmonic filters at the District Dairy Cooperative in Piątnica delivered measurable results:
- Significant reduction of harmonic levels
Relieving transformers and power cables increased the reliability of the entire electrical infrastructure. Equipment is less exposed to overheating, enabling longer and more reliable operation. - Improved process stability
The reduction of voltage fluctuations contributed to fewer downtimes and equipment failures, resulting in increased productivity on production lines. - Reduced energy costs
Reactive power compensation and the reduction of higher-order harmonic currents led to noticeable savings in electricity costs. - Increased safety and operational comfort
More efficient equipment operation and a lower number of failures translated into safer working conditions for personnel and improved maintenance efficiency.
Summary
The modernization of the electrical power system at the District Dairy Cooperative in Piątnica, based on ADF P300 active harmonic filters in a configuration consisting of three ADF P300-450A units, two ADF P300-375A units, and two ADF P300-250A units, proved to be an effective solution to power quality issues.
Harmonic reduction, dynamic reactive power compensation, and voltage stabilization significantly improved the efficiency and safety of the production process while delivering measurable financial benefits.
The cooperation with ANIRO resulted in an innovative and scalable solution, enabling OSM Piątnica to continue its growth while maintaining the highest standards of quality and power supply reliability. If your company faces similar power quality challenges, we encourage you to contact ANIRO to select the optimal solution.