Location: Alloa, Scotland
Industry: Malting
Partner: PFC Engineering
Timeline: 2025
Background
Crisp Malt in Alloa, Scotland, processes barley into malt used by breweries and distilleries across the UK and beyond. The site operates continuous production with large variable-speed drives and other non-linear loads that place heavy demands on the electrical network.
When irregularities began appearing in the site’s electrical performance, PFC Engineering, Comsys’ partner in the UK, was brought in to investigate. Their team carried out a full assessment of the existing power factor correction (PFC) system and the site’s overall power quality.
Challenge
The inspection revealed that the 300 kVAr PFC system was no longer performing as intended. Of its three stepped stages, two were operating with blown fuses, and the third was only partially functional. In practice, the site was receiving just 90 kVAr of compensation instead of the full 300 kVAr.
Subsequently, it was found that harmonic levels had also increased, confirming a clear link between the weakened PFC system and rising harmonic distortion.
The analysis also showed that the equipment had reached end-of-life and could not be repaired. Limited space inside the main low-voltage (LV) panel meant that any future detuned PFC system would have to be installed as a separate, freestanding unit. To make matters worse, high switchroom temperatures were placing additional stress on the components.
It was evident that simply replacing the old PFC would not resolve the underlying issue. A more comprehensive, harmonic-resistant solution was needed.
Solution
Following a detailed power quality analysis, PFC Engineering recommended installing an active harmonic filter to stabilize the network and prevent further issues.
A Comsys PPM300 was selected and integrated as part of a complete system solution developed by PFC Engineering. The system continuously monitors the electrical network in real time and automatically corrects harmonics, reactive power, and phase imbalance as conditions change.
The new filter was easily connected to the existing setup, and the ADF WUI interface provides the team with full visibility of performance data. Remote access and reporting make it simple to monitor system health and respond quickly if site conditions change.
Results
Since installation, Crisp Malt has seen a significant improvement in power quality and system stability. Harmonic levels have returned to within compliance limits, the power factor is now steady, and electrical equipment is running cooler and more reliably.
The solution has provided the site with a robust foundation for future growth and operational efficiency.
