Real Examples of How Businesses Reduced Electricity Costs and Freed Up Capacity
Electricity costs, power quality problems, and supply constraints often feel like unavoidable operational challenges. In practice, many of these issues can be resolved with the right analysis and the right technical solution.
These case studies show how businesses across South Africa addressed high electricity costs, limited electrical capacity, and power quality problems through practical interventions such as power factor correction and harmonic mitigation.
Each example illustrates how understanding the electrical behaviour of a site can lead to measurable savings, improved reliability, and the ability to expand operations without costly infrastructure upgrades.
For a full overview of these projects, you can also view the detailed case study document here:
Abattoir | Gauteng
Reducing Electricity Costs in a High-Energy Processing Facility
A large abattoir forming part of a national food processing company was looking for opportunities to reduce electricity costs at one of its Gauteng plants.
The facility relied heavily on electric motors, making electricity one of its largest operational expenses. After conducting a detailed assessment, Alpha Power Solutions installed power factor correction equipment designed for the plant’s load profile.
Results
• Investment: R395,000
• Payback period: Under 18 months
• Estimated savings over equipment lifetime: Over R4 million
The intervention reduced demand-related electricity charges while improving how the facility used power across its operations.
Poultry Farm | North West Province
Freeing Up Capacity Without Upgrading Electrical Supply
A poultry farmer wanted to add two additional chicken coops, but the existing transformer could not support the additional load.
Upgrading the supply would have been extremely expensive, so Alpha Power Solutions analysed the farm’s electrical profile and identified poor power factor as the main issue.
By installing a 100 kVAr power factor correction panel, sufficient capacity was freed up within the existing supply transformer.
Results
• Investment: R30,000
• Payback period: Under 2 months
• Enabled expansion to two additional coops housing 50,000 chickens
This solution avoided a costly electrical upgrade while allowing the business to grow.
Mineral Processing Plant | Gauteng
Reducing Maximum Demand Through Power Factor Correction
A mineral processing plant approached Alpha Power Solutions after noticing high electricity costs linked to demand charges.
Analysis showed the plant was operating with a power factor of 0.76. A properly sized power factor correction system was installed to improve the electrical performance of the site.
Results
• Investment: R210,000
• Reduction in maximum demand: 24%
• Monthly electricity savings: R15,000
• Payback period: 14 months
Improving power factor allowed the facility to reduce peak demand without affecting production.
Mineral Processing Plant | Gauteng
Reducing Maximum Demand Through Power Factor Correction
A steel fabrication company in the East Rand approached Alpha Power Solutions to help reduce their electricity costs.
The assessment revealed a very poor power factor of 0.39, which meant the plant was drawing significantly more apparent power from the grid than necessary.
After installing a tailored power factor correction system, the plant experienced a dramatic improvement.
Results
• Maximum demand reduction: 59%
• Monthly electricity savings: R21,000
• Payback period: 10.3 months
This intervention significantly improved the electrical efficiency of the plant
Car Component Manufacturer | Eastern Cape
Lowering Demand Charges in Automotive Manufacturing
A manufacturer producing automotive components needed help reducing maximum demand charges at its plant in Uitenhage.
The facility’s power factor was measured at 0.76. Installing a power factor correction system improved the site’s electrical performance and reduced demand charges.
Results
• Investment: R255,000
• Monthly savings: R17,500
• Payback period: 14.3 months
The system delivered predictable monthly savings while improving how the plant used power.
Paper Manufacturing Company | Eastern Cape
Rapid Implementation with Immediate Savings
A paper manufacturer in Gqeberha needed to determine the correct power factor correction requirements for its plant.
By analysing load profile data from the company’s online meters and electricity bills, Alpha Power Solutions was able to design and implement the system quickly.
Results
• Estimated payback period: 10 months
• Full project completion in less than one month
• Immediate electricity cost savings after installation
Accurate data analysis allowed the project to move from assessment to implementation quickly.
Plastics Manufacturer | Gauteng
Long-Term Electricity Savings
A plastics manufacturer invested in a 300 kVAr power factor correction panel to address high electricity costs.
Results
• Investment: R150,000
• Payback period: 11 months
• Total savings to date: Close to R1 million
This intervention demonstrates how relatively small investments can deliver significant long term savings.
Cool Drink Manufacturer | Limpopo
Solving Production Issues Caused by Harmonics
A bottling plant experienced production problems on a new bottling line. Initial investigations suggested a power quality issue.
Alpha Power Solutions conducted a detailed electrical network analysis and identified excessive harmonic distortion within the system.
Active harmonic filters were installed to mitigate the problem.
Results
• Harmonic levels reduced to acceptable limits
• Bottling line achieved full production capacity
This project demonstrated how power quality issues can directly affect operational performance.
Real Results from Real Facilities
These examples demonstrate that electricity challenges are often solvable with careful measurement and targeted interventions. Businesses frequently assume that high electricity costs or limited capacity require expensive upgrades.
In many cases, the right technical solution can reduce demand, improve power quality, and free up capacity within the existing electrical infrastructure.
POWER UP YOUR SAVINGS
We make it easy for you to start saving on electricity costs. Follow these three simple steps to get started.
1
CONTACT US
Call, email, WhatsApp, or fill out our form. We’ll align with your energy goals and start the conversation about reducing your electricity costs.
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2
SEND US YOUR ELECTRICITY BILL
We’ll analyse your bill to provide a preliminary cost/benefit analysis, showing you how much you could save.
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3
GET YOUR PERSONALISED SOLUTION
We’ll give you a tailored plan detailing your potential savings and the cost of the solution, so you can make an informed decision.
Struggling with high energy costs and lack of power capacity? Alpha Power Solutions offers simple, effective solutions so you can save money and expand your business.
