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Cutting-Edge Power Solutions: Energising Manufacturing Success
3 October 2024
In today’s manufacturing world, power is more than just electricity flowing through wires—it is the backbone of productivity, innovation, and growth. Whether you are running a massive industrial plant or a precision-driven processing facility, the success of your operations hinges on reliable, efficient, and uninterrupted power. But the power challenges that manufacturers face are as diverse as the industries themselves. From managing rising energy costs and meeting sustainability targets to preventing unplanned downtime and maintaining compliance with strict regulations, power is a central concern. As the manufacturing landscape continues to evolve, manufacturers need power solutions that not only meet their current needs but also prepare them for the future.
Let’s explore the diverse power challenges faced by different manufacturing industries and how cutting-edge solutions are helping manufacturers rise to these challenges.
Challenges Across the Manufacturing Spectrum
No matter the industry, manufacturers are united by a common set of challenges when it comes to power management:
Maintaining Power Quality
Manufacturing environments require consistent, high-quality power to keep operations smooth and equipment functioning correctly. However, power quality can fluctuate due to voltage sags, spikes, transients, and harmonics, all of which can lead to inefficiencies, financial losses, and equipment malfunctions. This is particularly problematic for semiconductors and pharmaceuticals, where even a minor fluctuation in voltage can result in costly disruptions.
For example, in semiconductor manufacturing, a brief voltage dip can damage wafers in production, wasting materials and time. Similarly, in pharmaceuticals, any deviation in power quality can impact the precise environmental controls required to maintain product safety. Below is the summary of the Power Quality Requirements.
Figure 1. Summary of Power Requirements at PCC
(Energy Market Authority, 2022; SP PowerGrid Ltd, 2015)
Energy Efficiency Demands
Energy is one of the most significant operational costs for manufacturers, making efficiency a critical focus. With rising energy costs (Macris, 2023) and increasing pressure to meet environmental and sustainability targets, manufacturers are constantly seeking ways to optimise their energy usage. However, optimising energy consumption is easier said than done. Industrial facilities, in particular, often use heavy-duty machinery that requires a substantial amount of energy. Without careful energy management, manufacturers risk overconsumption, resulting in higher operational costs and environmental impact. In addition, many sectors are turning to renewable energy sources, such as solar or wind, which require additional systems to manage integration with traditional grid power. In 2022, In Singapore, 41.3% (22.7TWh) of total electricity consumption (54.9TWh) is consumed by the Industrial-related sector.
Figure 2. Singapore Electricity consumption by sector, 2022
(Energy Market Authority, 2023)
Uninterrupted Operations
Unplanned downtime is the bane of manufacturing. When operations stop, revenue is lost, production schedules are thrown off, and entire supply chains can be disrupted (Macris, 2023). As a result, the average manufacturer confronts 800 hours of equipment downtime per year — more than 15 hours per week. That downtime comes at a significant cost. For instance, the average automotive manufacturer loses $22,000 per minute when the production line stops, which adds up to staggering figures (Ravande, 2022).
Across all industries, unplanned downtime costs industrial manufacturers as much as $50 billion annually (Coleman, Damodaran, & Deuel, 2017; Ravande, 2022; Shanker, 2021). In addition, 48% of respondents agreed that there are plenty room for improvement for overcoming equipment issues proactively (Vanson Bourne, 2017), such as predictive and preventative maintenance, instead of performing repairs after the equipment has broken down (Ravande, 2022).
This is particularly problematic in industries that rely on continuous processes, like semiconductors, where a sudden power outage can result in scrapped batches worth millions. FOr heavy industrial manufacturing, power failures not only halt production but also create dangerous safety hazards as large machinery grinds to an unplanned stop. Similarly, in the pharmaceutical industry, where temperature-sensitive processes are critical, even a brief disruption can compromise entire batches, leading to wasted resources and potential regulatory issues.
Regulatory Compliance
In many manufacturing sectors, particularly pharmaceuticals and food production, regulatory compliance is non-negotiable (Macris, 2023). As a result, power systems play a crucial role in maintaining the controlled environments needed. For instance, pharmaceutical manufacturing must adhere to Good Manufacturing Practices (GMP), which require stringent control of cleanrooms, temperature, and humidity levels (World Health Organisation, n.d.). Any disruption in power could lead to a lapse in regulatory compliance, resulting in product recalls, fines, or even legal action. Therefore, power systems in these environments must not only be reliable but also designed to ensure continuous monitoring and reporting to meet regulatory standards.
Scalability and Adaptability
Meeting the Demands of Industry 4.0
As industries expand and adopt new technologies, their power infrastructure must keep pace. However, traditional power systems, which often is rigid and difficult to scale, make it challenging for manufacturers to meet increasing demands. With the rise of Industry 4.0 technologies—such as automation, robotics, and IoT devices—the need for adaptable, scalable power solutions is more critical than ever. According to a McKinsey analysis, up to 58% of manufacturing activities can already be automated with today’s technology (McKinsey & Company, 2022), underscoring the urgency for more flexible power systems.
The Impact of Automation on Power Needs
Take, for example, the global industrial robot market, which was valued at USD 16.78 billion in 2022 and is projected to grow to USD 41.02 billion by 2030, at a CAGR of 12.3%. This rapid growth clearly illustrates the increasing reliance on automation to enhance efficiency and productivity. Furthermore, Asia Pacific, holding a dominant 48.98% market share, is leading the charge in this transformation. In short, as factories worldwide integrate more robotics, the demand for reliable and scalable power solutions rises in parallel (Fortune Business Insights, 2024).
The Rise of IoT and Its Power Implications
The demand for flexible power infrastructure does not stop at automation. By the end of 2023, there were 16.6 billion IoT devices globally, and this number is projected to grow 13% to 18.8 billion by the end of 2024 (Sinha, 2024), and even further to 27 billion by 2025 (Coughlin, 2024). Likewise, in the healthcare sector alone, IoT integration is expected to reach $150 billion in 2024 and grow to $289 billion by 2028 (Marr, 2023). As these technologies proliferate, they bring new layers of complexity and power demands.
Power Systems for Evolving Industries
For instance, semiconductor fabs, driven by the growing demand for consumer electronics, electric vehicles, and AI technologies, require power systems that can scale seamlessly as their operations expand. In a similar way, these fabs, much like industrial manufacturers, need modular and flexible power solutions that can be easily upgraded or expanded to support new technologies and increasing production capacities. As a result, the challenge lies in ensuring that power systems are not only sufficient for today’s demands but also adaptable enough to meet the future needs of rapidly evolving industries.
Industry-Specific Power Challenges
Every manufacturing industry is like its own world, each with its own rules, priorities, and power demands. Although many industries share common challenges, the reality is that the way they experience and address power issues is entirely unique to the products they create. With that in mind, let’s take a journey through some of these sectors and explore the power-related challenges they face in their day-to-day operations.
Semiconductor Manufacturing: Precision and Stability in a Microscopic World
The Challenges of Precision in Semiconductor Manufacturing
Semiconductor manufacturing is all about precision. Imagine working in a high-tech fab where the products you are creating are mere nanometres in size—smaller than a single grain of sand. In this environment, even the slightest voltage fluctuation or a momentary power loss can lead to disastrous consequences. A blip in power could turn expensive silicon wafers into scrap, disrupting production and wasting millions of dollars in materials and time.
To overcome this, Dynamic Rotary Uninterruptible Power Supply (DRUPS) systems provide the stability semiconductor fabs need. By combining mechanical energy storage with uninterrupted power, DRUPS ensures that even the tiniest fluctuations in voltage are smoothed out, protecting sensitive equipment, and ensuring a steady stream of high-quality power. It is like having a shield around your entire facility, protecting it from the outside world’s unpredictability.
Solutions for Reliable Power and Cleanroom Conditions
But that’s not the only challenge semiconductors face. Many fabs rely on cleanrooms—spaces where the air is meticulously filtered to prevent even microscopic particles from contaminating the products. Maintaining the precise temperature, humidity, and air quality in these rooms requires a stable power system. If the power to the HVAC or filtration systems falters, cleanroom conditions can deteriorate, compromising the entire production process.
To solve this, manufacturers are turning to Energy Storage Systems (ESS). During off-peak times, these systems store excess energy and release it when needed, ensuring a continuous, stable power supply to critical systems like HVAC. ESS also provides a sustainable solution, allowing semiconductor manufacturers to integrate renewable energy sources into their operations, reducing costs and environmental impact.
Finally, as the demand for semiconductors skyrockets, fabs need to scale up their production quickly. This requires Modular Power Solutions—scalable systems that can expand alongside the facility without major overhauls. With modular solutions, semiconductor manufacturers can adapt their power infrastructure to meet the growing demands of production while maintaining the same level of reliability and efficiency.
Industrial Manufacturing: Keeping the Machines Running Smoothly
The High Stakes of Power in Industrial Manufacturing
Everything operates on a grand scale in the world of industrial manufacturing. Massive machines churn out steel components, assembly lines buzz with activity, and everything is running on a tight schedule. Downtime is not just inconvenient—it is expensive and dangerous. Imagine the entire factory floor grinding to a halt because of a power failure. Restarting these complex machines is not easy, and each minute lost translates into financial losses.
This is where Energy Storage Systems and Uninterruptible Power Supplies (UPS) come into play. By providing backup power during outages, these systems ensure that the factory floor never stops, even when external power is compromised. Industrial manufacturers can rely on ESS to balance energy loads, reducing stress on the grid and minimising downtime. UPS systems kick in instantly during outages, preventing costly interruptions.
Ensuring Power Quality and Efficiency
But it is not just about preventing outages—power quality is another critical factor in industrial settings. For instance, power surges, sags, or harmonics can cause wear and tear on heavy machinery, reducing efficiency and increasing maintenance costs. To mitigate these power quality issues, voltage regulators and harmonic filters are essential. These solutions smooth out inconsistencies in the power supply, protecting equipment and optimising energy use.
The industrial sector also faces rising energy costs and increasing pressure to reduce its environmental impact. To tackle this, manufacturers are using Energy Management Systems (EMS), which provide real-time insights into energy consumption patterns. EMS helps identify inefficiencies and offers opportunities to cut costs by optimising power usage without compromising productivity. Paired with Power Distribution Units (PDUs), which monitor and control energy distribution, industrial facilities can fine-tune their power systems for maximum efficiency.
Pharmaceutical Manufacturing: Precision Meets Power Stability
The Critical Importance of Power in Pharmaceutical Manufacturing
In pharmaceutical manufacturing, precision is not just about product quality—it is about safety. Every process, from drug formulation to packaging, must adhere to strict regulations like Good Manufacturing Practices (GMP). These rules ensure that medicines are produced in controlled environments, free from contamination, and stored at specific temperatures to maintain their efficacy.
One of the biggest challenges in this industry is regulatory compliance. Power disruptions can compromise cleanroom environments, where drugs are produced, or affect the refrigeration systems storing temperature-sensitive vaccines. A loss of power could lead to contamination or spoilage, putting patient safety at risk and resulting in significant financial and legal repercussions.
Solutions for Maintaining Compliance and Safety
To combat this, pharmaceutical manufacturers are turning to Cleanroom Power Systems combined with Dynamic Rotary UPS solutions. DRUPS systems provide the ultra-reliable power needed to maintain the precise conditions required in cleanrooms, while also offering protection against voltage fluctuations that could compromise production. Cleanroom environments are safeguarded by advanced cooling systems that keep air quality and temperature stable, ensuring compliance with stringent regulations.
For temperature-sensitive processes, Energy Storage Systems (ESS) play a crucial role. They ensure that refrigeration and other critical systems remain operational during outages. ESS provides a seamless and reliable backup power source, preventing the spoilage of valuable products. Paired with Power Distribution Units (PDUs), which offer real-time monitoring and control, pharmaceutical manufacturers can ensure that power systems are running optimally, maintaining the delicate balance needed for product safety.
Striving for Energy Efficiency
Just like in other industries, pharmaceutical manufacturers are also focused on reducing their energy footprint. Energy-efficient solutions, such as advanced cooling and ventilation systems, help reduce power consumption without sacrificing the stringent environmental controls that are essential for product quality.
A Future Powered by Innovation
Across the entire manufacturing spectrum, power remains a critical factor in ensuring operational excellence, and the challenges are as diverse as the industries themselves. For example, from the microscopic world of semiconductors to the massive machinery of industrial manufacturing, as well as the life-saving precision of pharmaceuticals, reliable and efficient power systems are essential for success.
To address these challenges, manufacturers are embracing innovative solutions like Dynamic Rotary UPS systems, Energy Storage Systems, Modular Power Solutions, and Expert Consultation Services. By doing so, they can rise to meet the demands of today’s fast-evolving landscape. These power technologies not only prevent costly downtime but also improve energy efficiency, reduce environmental impact, and allow for seamless scalability.
Ultimately, powering manufacturing excellence is about more than just keeping the lights on. In fact, it is about enabling innovation, maintaining precision, and ensuring that each industry continues to thrive and grow. With the right power solutions in place, manufacturers can meet their goals, reduce risks, and pave the way for a brighter, more efficient future.
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References
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