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PAL Group (Operations) Ltd, a UK-based trade thermoplastic extruder with over 30 years of industry experience, operates its entire facility from a single HV-fed transformer. Therefore, reliability is critical. With no redundancy on site, any transformer failure would bring production to a standstill. At the same time, the site was operating with a 1000kVA transformer installed in 1974, which was no longer energy efficient and was contributing to unnecessary energy losses and higher operational costs.
To reduce energy costs across the site, PAL Group required a modern, energy-efficient transformer delivered within a tight timeframe.
Bowers Electricals was selected due to our ability to provide a rapid transformer replacement programme, combining efficient manufacturing, delivery and coordinated installation.
Following a detailed site assessment, Bowers Electricals proposed upgrading the ageing unit to a Tier 2 Ecodesign-compliant distribution transformer. Tier 2 transformers are specifically designed to reduce no-load and load losses, helping industrial sites lower wasted energy and achieve measurable long-term energy cost savings.
The new transformer supplied was a 1000kVA, 11,000V to 415V, three-phase, 50Hz aluminium-wound distribution transformer, ONAN cooled and fully compliant with Tier 2 regulations.
Compared to the 1974 unit, this energy-efficient transformer significantly reduces electrical losses at the point of distribution, directly contributing to reduced energy costs and improved overall system performance.
One of the key challenges of the transformer replacement was the site’s reliance on a single HV feed. The changeover had to be carefully planned and executed to avoid production downtime. Detailed risk management and experienced on-site supervision were therefore central to the project.
This provided hands-on support during the transformer exchange, assistance with the HV installation and full oversight of testing and commissioning. Every stage of the transformer upgrade was managed to minimise downtime and ensure a seamless transition to the new energy-efficient system.
By replacing a 50-year-old transformer with a modern Tier 2 distribution transformer, PAL Group has significantly reduced energy losses across its electrical infrastructure.
The upgrade not only improves reliability for a single-transformer site but also delivers ongoing energy cost savings through improved efficiency and reduced wasted power.
Following discussions around transformer maintenance and asset management, PAL Group committed to one of Bowers Electricals’ transformer service plans. This ensures the new energy-efficient transformer continues operating at peak performance, protecting the investment and supporting long-term energy cost reduction.
PAL Group (Operations) Ltd supplies high-performance plastic extrusions across sectors, including office furniture, partitioning, automotive, shop fitting, building, caravan, leisure and medical industries. Their continued investment in infrastructure improvements, including this energy-efficient transformer replacement, supports consistent product quality, reliable performance and cost-effective manufacturing.
By combining rapid turnaround capability, detailed project planning and energy-efficient transformer technology, Bowers Electricals enables customers to cut losses, lower operational costs and future-proof their electrical infrastructure.
