Power Factor Correction for Mineral Processing Plants Case Study
REDUCE YOUR MINERAL PROCESSING PLANT’S ELECTRICITY COSTS WITHOUT CUTTING PRODUCTION
Power factor correction solutions that help mineral processing plants reduce avoidable demand charges, improve electrical performance, and lower operating costs.
📞 Call 011 615 4640 or fill out the form to get started.
Reduce avoidable demand charges
Lower monthly electricity costs
Maintain production output
ARE DEMAND CHARGES DRIVING UP YOUR PLANT’S ELECTRICITY BILL?
High electricity costs can put pressure on your mineral processing operation’s margins. But reducing your bill does not always mean reducing production.
For one Gauteng mineral processing plant, poor power factor was contributing to high demand charges. Addressing the problem reduced maximum demand by 24% without affecting production.
Could your plant be paying for electrical inefficiencies that can be corrected?
High demand charges increasing your monthly electricity bill
Rising operating costs putting pressure on margins
Uncertainty about your plant’s power factor
Pressure to reduce costs without reducing production
Limited visibility into potential savings and payback
SPEND LESS ON ELECTRICITY WITHOUT COMPROMISING PRODUCTION
Your plant needs to keep producing. Our goal is to help you identify avoidable electricity costs and understand whether power factor correction can reduce them.
We assess your site’s electrical requirements and explain the potential savings, installation cost, and payback period so you can make an informed business decision.
LOWER YOUR ELECTRICITY COSTS
Find out whether poor power factor is contributing to unnecessary demand charges. A solution tailored to your plant can help address these costs and reduce your monthly electricity bill.
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GET A RETURN YOU CAN MEASURE
Understand the numbers before you invest. We help you assess the cost of the solution against the potential monthly savings, giving you a clear basis for evaluating the investment.
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IMPROVE ELECTRICAL PERFORMANCE
Address poor power factor with a properly sized correction system. At the Gauteng mineral processing plant featured below, this approach reduced maximum demand by 24% without affecting production.
WE’VE BEEN HELPING ENERGY-INTENSIVE BUSINESSES SAVE FOR OVER 30 YEARS
Reducing electricity costs starts with understanding how your site uses its electrical supply—and where avoidable costs may arise.
Alpha Power Solutions helps businesses across South Africa identify electrical inefficiencies and implement solutions tailored to their operations.
Over 30 years of experience
Specialists in power factor correction and harmonics filtration
Trusted by energy-intensive industries across Southern Africa
Recognised by SAEEC, ECASA, and SANEDI
Tailor-made solutions based on each site’s electrical requirements
When the numbers make sense, improving electrical performance becomes a business decision—not just a technical one.
MINERAL PROCESSING PLANT
CASE STUDY
Investment in Power Factor Correction
R210,000
Payback Period
14 Months
Reduction in Maximum Demand
24%
R15,000
Monthly Electricity Savings
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REAL RESULTS FROM A MINERAL PROCESSING PLANT IN GAUTENG
A mineral processing plant in Gauteng approached Alpha Power Solutions after noticing high electricity costs linked to demand charges.
Analysis of the site’s electrical performance showed that the plant was operating with a power factor of 0.76.
Alpha Power Solutions installed a properly sized power factor correction system to improve the site’s electrical performance and address the avoidable demand costs.
The result was a 24% reduction in maximum demand, saving the plant R15,000 per month without affecting production.
The installation required an investment of R210,000, with a payback period of 14 months.
Every mineral processing plant is different, but this project demonstrates the value of investigating power factor before assuming that lower electricity costs require lower production.
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.
TRUSTED BY INDUSTRY LEADERS
Our proven solutions have helped businesses across a wide range of industries save on electricity costs and improve efficiency. Here are just a few of the companies that trust Alpha Power Solutions to optimise their energy usage and keep their operations running smoothly.
Beefmaster
Tiger Brands
Coca-Cola
Spar
Unilever
INDUSTRIES THAT BENEFIT FROM OUR SOLUTIONS
Our energy-saving solutions are tailored to meet the needs of various industries. Whether you're in manufacturing, food processing, or retail, we help businesses like yours cut electricity costs, improve efficiency, and reduce downtime. Explore how we can support your industry.
| Abattoirs | Bakeries | Breweries & cooldrink bottlers |
| Brick manufacturers | Cable manufacturers | Cement product manufacturers |
| Chemical manufacturers | Cold storage facilities | Component & parts manufacturers |
| Dairy products processors | Data centres | Distribution centres |
| Food processing plants | Large retailers | Large warehouses |
| Metal fabricators | Metal packaging manufacturers | Metal recyclers |
| Millers (flour, animal feeds, etc) | Mineral processors | Paper & cardboard manufacturers |
| Paper & cardboard printers | Paper & plastic packaging manufacturers | Paper mills (modern & traditional) |
| Pharmaceutical manufacturers | Plastic recyclers | Plastics product manufacturers |
| Industrial chicken farms | Saw mills & wood processors | Tobacco product manufacturers |
PFC Case studies
Industry results
FURNITURE MANUFACTURING PLANT
Case Study
Cost of PFC installation
R100,000
Monthly saving
R8,700
Savings over 10 years
R1,500,000
R1,500,000
savings
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WOOD PROCESSING PLANT
Case Study
Cost of PFC installation
R73,500
Monthly saving
R3,100
Savings over 10 years
R470,000
R470,000
savings
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FOOD PROCESSING PLANT
Case Study
Cost of PFC installation
R1,250,000
Monthly saving
R84,500
Savings over 10 years
R13,520,000
R13,520,000
savings
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ABATTOIR
Case Study
Cost of PFC installation
R580,000
Monthly saving
R110,000
Savings over 10 years
R21,000,000
R21,000,000
savings
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ALUMINIUM PROCESSING PLANT
Case Study
Cost of PFC installation
R525,000
Monthly saving
R75,000
Savings over 10 years
R12,000,000
R12,000,000
savings
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FLOUR MILL
Case Study
Cost of PFC installation
R175,000
Monthly saving
R17,000
Savings over 10 years
R2,200,000
R2,200,000
savings
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With 80+ years of combined PFC expertise and recognised credentials from SAEEC and ECASA, Alpha Power Solutions is trusted by industrial businesses across South Africa to deliver proven energy efficiency results.
Our Power Factor Calculator gives you a quick, clear estimate of how much you could save. By analysing your power usage and current demand, it helps you understand the financial impact of installing a power factor correction system—before you commit to anything.
Use the calculator to:
Estimate your current power factor
See how much demand you could cut
Get a savings estimate based on your actual usage
It’s fast, accurate, and backed by real industry data. Businesses using our systems typically see savings of up to 20%, with many projects delivering payback in under 18 months. Start with the calculator to see what’s possible.
For businesses that have reached the maximum of their electrical supply, the average cost of a PFC solution to free up supply capacity is usually 85% more cost-effective than an electrical supply upgrade.
YOU DON'T HAVE TO GUESS WHETHER IT'S WORTH THE INVESTMENT
You know what your plant pays for electricity. What may be less clear is how much of that cost could be avoided.
Alpha Power Solutions assesses your electrical requirements, identifies opportunities for power factor correction, and explains the financial case in plain language.
With a clear view of the installation cost, potential monthly savings, and expected payback period, you can decide whether the investment makes sense for your operation.
For the Gauteng mineral processing plant featured here, that meant R15,000 in monthly savings and a 14-month payback period—without affecting production.
I want to reduce my Power/electricity cost
Tailor made solutions to help you reduce electricity costs by up to 20%, call now or use the form to send us your requirements.
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.
