HV switchgear upgrade improves production reliability for leading brewery manufacturer

Project summary:

• Sector: Feed, Food & Beverage
• Client: Leading Brewery Manufacturer
• Location: Burton upon Trent, United Kingdom
• Expertise: HV Compliance & Maintenance | HV Switchgear | Electrical Installation, Testing & Commissioning

Project at a glance:

• 25-30-year-old switchgear replaced to address obsolescence
• £100,000 project value
• 13-month programme from planning to completion
• 110,000 litres per day production capacity protected
• Individual transformer isolation then possible without wider shutdowns
• Modern Schneider Electric switchgear installed and commissioned
• Ongoing HV maintenance contract secured following project completion

The challenge: Managing ageing infrastructure in a live production environment

A leading brewery manufacturer identified increasing concerns with HV switchgear that had been in operation for more than 25 years. The equipment had become obsolete and was subject to operational restrictions that limited the site’s ability to safely isolate individual transformers during routine maintenance.

As a result, maintenance on a single transformer or LV panel often required wider electrical shutdowns, creating operational challenges for a site that relied on continuous production.

The situation became even more critical when a switch mechanism failed to return correctly to its operational position following maintenance, resulting in blown fuses. Further investigation highlighted the deteriorating condition of the equipment and the need for remedial action as part of the site’s ongoing management of its HV assets.

Producing approximately 110,000 litres per day, the brewery customer understood that prolonged electrical failure could significantly disrupt its operations, increase costs and impact production schedules. They therefore required a modern replacement solution that would improve operational flexibility, simplify maintenance activities and reduce the risk of unplanned downtime.

The project also required careful planning, as shutdown activities needed to be coordinated around production requirements, leaving little margin for delays during installation and commissioning.

The solution: Modernising critical HV infrastructure

Drawing on its extensive expertise in HV compliance and power distribution systems, Actemium Birmingham, part of Actemium UK developed and delivered a complete switchgear replacement solution tailored to the site’s operational requirements.

The project included:

• Review of the existing electrical distribution network
• Protection studies and relay coordination
• Development of new protection settings
• HV switching and isolation planning
• Removal of ageing oil-filled switchgear
• Installation of new Schneider Electric Ringmaster switchgear
• Testing, commissioning and re-energisation

One of the most critical elements of the project was the development of a detailed switching strategy. The brewery’s electrical infrastructure supplied multiple transformers and plant areas across the site, making careful sequencing essential.

Actemium engineered a sophisticated switching programme that enabled the required section of the network to be isolated while maintaining power to the remainder of the facility. This minimised disruption while allowing the remedial work to be completed safely within the available outage window.

During the planned shutdown, the existing switchgear was replaced with a modern Schneider Electric Ringmaster solution incorporating CE2 protection equipment. Temporary power arrangements were used where required to maintain site operations.

Following testing, commissioning and re-energisation, the modernised HV network was returned to service safely, on programme and with minimal impact on production.

Results and benefits: Improved reliability, flexibility and business continuity

The completed switchgear upgrade strengthened the site’s electrical resilience by replacing ageing infrastructure with a modern, more maintainable HV system.

Key benefits included:

• Supported HV compliance and reduced operational risk: Replacing obsolete switchgear addressed identified asset condition issues and reduced reliance on equipment subject to operational restrictions.
• Improved reliability and maintenance flexibility: The modern switchgear provided greater confidence in the HV network, while allowing individual transformers to be safely isolated without wider site shutdowns.
• Protected production and business continuity: Improved electrical resilience reduced the risk of unexpected outages affecting brewing operations producing around 110,000 litres per day and employing over 300 people.
• Minimised maintenance costs: Improved asset condition and greater isolation flexibility lowered the need for emergency interventions.
• Greater future readiness: The modernised HV network provides a more maintainable electrical foundation for future operations.

The customer also avoided potentially significant emergency intervention costs, with specialist out-of-hours isolation activities estimated at approximately £1,000 per hour.

Following successful delivery, Actemium strengthened its relationship with the customer and secured an ongoing HV maintenance contract for activities across the site.

Electrical compliance expertise from Actemium UK

For manufacturers operating around-the-clock production, ageing electrical infrastructure can increase operational risk, restrict maintenance and leave critical processes vulnerable to unplanned outages. Actemium UK helps industrial customers identify these risks and develop practical upgrade strategies that improve reliability while minimising disruption.

Our expertise spans all stages of HV compliance, including HV maintenance, switchgear replacement, protection engineering, electrical installation, testing and commissioning, helping customers modernise critical infrastructure safely and efficiently. By combining technical expertise with an understanding of operational environments, we help reduce risk, improve asset reliability and prepare infrastructure for future demands.