CleanVolt Real World Results: Driving Energy Efficiency in an Industry-Leading Food & Beverage Production Facility
Industrial facilities depend on stable power to keep operations running efficiently. Even small electrical disturbances—such as voltage sags, harmonic distortion, or current surges—can lead to overheating equipment, increased maintenance costs, and unnecessary energy consumption.
A recent installation of CleanVolt power quality technology at a leading food and beverage manufacturing facility demonstrates how addressing power quality issues can significantly improve operational efficiency while reducing energy costs.
Project Overview
The project focused on improving the power quality within the facility’s blow mold production section. Four CleanVolt units were installed across key electrical panels in July 2023.
Installation locations included:
- Main Panel
- Blow Mould Panel
- Descon Panel
- DP-N1 Panel
Prior to installation, detailed power analysis was conducted using Dranetz power logging meters to measure electrical disturbances and energy usage.
Project Timeline
Key Results After Installation
Significant Reduction in Power Faults
Power disturbances such as:
- Voltage sags
- Voltage interruptions
- Voltage swells
- Voltage transitions
can cause equipment failures and operational disruptions.
After the CleanVolt installation, monitoring data showed a dramatic reduction in daily triggered power faults across several electrical panels within just two months of operation.
Reducing these faults helps:
- Protect sensitive electrical equipment
- Reduce unplanned downtime
- Improve overall power stability
Lower Electrical Component Temperatures
Excess electrical heat is often a symptom of poor power quality and electrical resistance within a system.
Thermal imaging taken before and after the CleanVolt installation showed lower maximum component temperatures across multiple panels, even though the post-installation measurements were taken during warmer ambient conditions.
Lower operating temperatures contribute to:
- Longer equipment lifespan
- Reduced maintenance requirements
- Lower risk of electrical failures
Measurable Energy Efficiency Improvements
Energy usage was analyzed by comparing kWh consumed per unit of production before and after installation.
Results showed:
- Average energy usage before installation: 0.341 kWh per unit
- Average energy usage after installation: 0.282 kWh per unit
This represents an energy reduction of approximately 17%.
Monthly Cost Savings
Using the facility’s production data and electricity billing rates, the results translated into meaningful financial savings.
Average results from the blow mold production line:
- 17% reduction in energy consumption
- Approximately $2,037 in monthly after-tax savings
- About 12.5% reduction in overall monthly power costs
With an average monthly power bill of roughly $16,263, these savings represent a substantial operational improvement.
Potential Savings Across the Entire Facility
Based on the results from the blow mold production section, the facility estimated the impact of installing CleanVolt at the main electrical entrance and all sub services for the larger portion of the plant.
Projected savings:
- ~$5,600 per month
- ~$67,200 per year
Additional benefits are expected to include further reductions in power faults, maintenance costs, and equipment wear.
How CleanVolt Technology Works
Once installed, CleanVolt devices begin addressing electrical disturbances within the system immediately.
Electrical systems commonly produce internal current surges caused by:
- Load cycling
- Counter-electromotive force (CEMF) from motors
- Harmonic distortion from electronic equipment
These surges generate heat and electrical resistance within the system. Over time, this resistance increases energy consumption and reduces system efficiency.
CleanVolt technology works by:
- Attracting and dissipating these current surges as heat
- Reducing electrical noise on phases and neutral lines
- Allowing the system to gradually return to more efficient operating conditions
Depending on system complexity and conductor length, efficiency improvements typically become fully visible within 30–90 days after installation.
The Bigger Picture: Power Quality Matters
Improving power quality delivers benefits beyond energy savings. Facilities that implement CleanVolt technology often see improvements such as:
- Reduced power faults
- Lower electrical component temperatures
- Longer equipment lifespan
- Reduced maintenance costs
- Improved operational reliability
- Lower energy consumption
Together, these improvements help industrial facilities operate more efficiently while protecting critical infrastructure.