Designing Electrical Systems for Industrial Facilities

Designing Electrical Systems for Industrial Facilities: A Case Study of a international food and beverage factory

Industrial facilities such as food and beverage manufacturing plants demand robust, efficient, and reliable electrical systems to ensure uninterrupted operations, meet stringent quality standards, and maintain energy efficiency. This blog takes an in-depth look at the electrical system design for a international food and beverage factory, illustrating the unique requirements and innovative solutions implemented in such a facility.

Overview of the International Industrial Facility

International food and beverage manufacturing plants are complex operations that include:

High-powered production lines for food and beverage processing.

Cold storage and refrigeration systems.

Packaging and labeling machinery.

HVAC systems for maintaining product safety and employee comfort.

Administrative offices and employee facilities.

Designing an electrical system for such a facility requires a comprehensive approach that addresses power reliability, energy efficiency, and safety.

Key Components of the Electrical System Design

Power Supply and Distribution

Utility Connection: The facility is connected to a medium-voltage (MV) utility grid to accommodate the high power demand of the factory. The incoming voltage is typically stepped down to low voltage (LV) through transformers for internal distribution.

Main Distribution Board (MDB): The MDB serves as the primary control hub, feeding power to various sections of the factory, including production, HVAC, and lighting systems.

Subpanels and Zoning: Power is distributed across zones such as processing areas, storage, and administrative spaces, each with dedicated subpanels to ensure manageable load distribution and system isolation during maintenance.

Backup Power Systems

To prevent costly downtime during power outages, the facility is equipped with robust backup systems:

Diesel Generators: These provide immediate power to critical systems like production lines, refrigeration units, and IT infrastructure.

Uninterruptible Power Supply (UPS): Used for sensitive equipment like control systems, preventing data loss and abrupt shutdowns during power interruptions.

Automatic Transfer Switches (ATS): Ensure seamless switching between utility and backup power sources.

Energy Efficiency and Sustainability

High-Efficiency Motors: Motors used in pumps, compressors, and conveyors are selected for their high efficiency to reduce energy consumption.

Variable Frequency Drives (VFDs): VFDs are installed on motors to adjust speed and power consumption based on operational demands, particularly in HVAC and conveyor systems.

LED Lighting: Energy-efficient LED lighting is used throughout the facility, including production areas, offices, and external spaces.

Renewable Energy Integration: Solar panels installed on rooftops or open areas supplement the facility's energy needs, reducing reliance on grid power.

Electrical Safety Systems

Grounding and Bonding: Comprehensive grounding systems ensure the safe dissipation of fault currents and protect against electrical hazards.

Circuit Protection: Circuit breakers, fuses, and residual current devices (RCDs) protect against overloads, short circuits, and ground faults.

Hazardous Area Classification: Certain zones, such as those handling flammable materials or powders, require explosion-proof electrical equipment in compliance with international safety standards.

Automation and Control Systems

Supervisory Control and Data Acquisition (SCADA): SCADA systems monitor and control the facility’s electrical network, ensuring optimal performance and quick fault detection.

Programmable Logic Controllers (PLCs): PLCs control automated processes such as mixing, packaging, and labeling, ensuring precision and repeatability.

Energy Management Systems (EMS): EMS provides real-time monitoring of energy usage, enabling facility managers to identify inefficiencies and implement corrective actions.

Design Challenges and Solutions

High Power Demand

Challenge: The factory’s heavy machinery and 24/7 operations result in substantial power consumption.

Solution: The design incorporates a high-capacity transformer and a dual-feed utility connection for reliability. Load balancing and power factor correction equipment are used to optimize the power system.

Temperature Control for Refrigeration Systems

Challenge: Refrigeration units require a constant power supply to maintain product integrity.

Solution: Backup generators with sufficient capacity and dedicated circuits ensure uninterrupted operation.

Compliance with Food Safety Standards

Challenge: Electrical systems must meet hygiene and safety standards in food manufacturing areas.

Solution: All electrical installations in production zones use stainless steel enclosures with IP-rated protection to withstand washdowns and prevent contamination.

Space Constraints

Challenge: Electrical rooms and cable routing must fit within the factory’s layout while remaining accessible for maintenance.

Solution: Compact switchgear and modular busbar trunking systems are used to optimize space. Vertical cable risers minimize horizontal routing in high-density zones.

Case Study: Electrical System Highlights

A Nestlé facility in Southeast Asia showcases innovative electrical system design:

Power Generation: A 500-kW rooftop solar PV system offsets 20% of the factory’s energy demand.

Integrated Automation: A SCADA system monitors energy consumption, ensuring efficient production scheduling and reduced peak loads.

Cold Chain Reliability: UPS systems with lithium-ion batteries provide extended runtime for refrigeration units.

Safety First: Explosion-proof lighting and equipment are installed in areas handling flammable ingredients, ensuring compliance with safety regulations.

Conclusion

Designing electrical systems for industrial facilities like international food and beverage factories requires a deep understanding of operational demands, safety standards, and energy efficiency. By integrating robust power distribution, reliable backup systems, and advanced automation, engineers can ensure seamless operations while minimizing environmental impact. This case study highlights how thoughtful design and adherence to best practices can create electrical systems that power productivity while meeting sustainability goals.