In the plastic film production sector, the reliability of the power supply is a critical factor for production continuity and for the quality of the finished product. In plants where extrusion and processing take place continuously, even short voltage micro‑outages or sags can cause unexpected machine shutdowns, material scrap and significant additional costs.
THE CHALLENGE: VOLTAGE MICRO‑INTERRUPTIONS AND HIDDEN COSTS
In the plastics industry, even short voltage drops can cause serious consequences. Modern production lines, highly automated and controlled by sensitive electronic systems, are immediately affected by these disturbances. A single event can lead to the immediate stop of injection moulding machines, the shutdown of extrusion lines and the loss of material being processed, with costs estimated between 5.000 and 50.000 euro for each hour of downtime, according to the most recent ARERA data.
THE ECONOMIC IMPACT OF PRODUCTION STOPPAGES: A REAL CASE STUDY
DISTURBANCE ANALYSIS: 600 MICRO INTERRUPTIONS PER YEAR
A major industrial group in Southern Italy, specialised in the production of plastic films for the agricultural and industrial sectors, recorded about 600 micro interruption events per year through an in-depth measurement campaign, with voltage drops down to 90% of nominal. This frequency, although within the parameters of IEC EN 50160, proved incompatible with the company’s production needs.
QUANTIFYING HIDDEN COSTS (SCRAP, LABOUR, ENERGY)
The company’s energy manager quantified the overall economic impact of these disturbances, which included:
- Sudden stoppages of extrusion and winding lines
- Impairment of the quality of the material being processed during transients
- Increase in production scrap and energy costs for restarts
- Negative impact on productivity and compliance with delivery times
The phenomenon affected all three production plants, with losses that management estimated at over 200.000 euro per year considering direct and indirect costs.
THE TECHNICAL DIAGNOSIS BY THE ORTEA TEAM
The Ortea technical team carried out a specialised analysis of network disturbances, identifying the specific characteristics of the events and the most sensitive loads by means of dedicated instruments. This diagnostic phase proved essential to correctly size the solutions and ensure maximum return on investment.
OXYGEN ZERO: THE DEFINITIVE SOLUTION AGAINST VOLTAGE MICRO‑INTERRUPTIONS
HOW THE BATTERY-FREE TECHNOLOGY WORKS
Oxygen Zero represents the most advanced technological evolution for protection against voltage micro interruptions. Based on a high-efficiency electronic technology that uses supercapacitors instead of traditional batteries, the system delivers significant advantages in terms of reduced maintenance, environmental sustainability and operational reliability.
The device intervenes automatically in a few milliseconds, instantly detecting the voltage drop and restoring the nominal level before sensitive loads can be affected.
MAIN TECHNICAL FEATURES AND BENEFITS
Oxygen Zero offers superior performance compared to traditional solutions:
- Automatic compensation of voltage drops up to 100%
- Response time below 3 milliseconds, in line with the most advanced market standards
- Battery-free technology that reduces maintenance costs and environmental impact
- Complete protection of sensitive machines and production lines
INSTALLED CONFIGURATIONS FOR PRODUCTION LINES
For the case study mentioned, Ortea supplied an integrated and customised solution for all four main production lines:
- Oxygen Zero 1000K (Line 1)
- Oxygen Zero 1000K with integrated 4x250A automatic circuit breaker (Line 2)
- Oxygen Zero 1500K (Line 3)
- Oxygen Zero 500K (Line 4)
This configuration represents an investment that, according to company estimates, paid for itself in less than 18 months thanks to the elimination of production stoppages caused by micro interruptions.
Discover the technical details of the Oxygen Zero range
WHY CHOOSE ORTEA NEXT FOR YOUR PLANT’S POWER QUALITY
MORE THAN 50 YEARS OF EXPERIENCE IN VOLTAGE STABILITY
Ortea, founded in 1969, boasts more than fifty years of experience in the power quality sector, with a consolidated presence in more than 100 countries worldwide. This experience translates into unique specialist expertise in the analysis of network disturbances and the development of customised solutions for every type of industrial plant.
CUSTOM SOLUTIONS COMPLIANT WITH STANDARDS
Ortea’s approach is based on customisation: each solution is designed and sized specifically for the characteristics of the plant and the customer’s production needs. All products strictly comply with European and international standards for power quality and the conformity directives for CE marking.
A PARTNER FOR ENERGY EFFICIENCY AND OPERATIONAL CONTINUITY
Choosing Ortea means relying on a complete technical partner, capable of supporting companies from the initial diagnostic phase to after-sales support. The Made in Italy quality of the products, combined with the global network of specialised distributors, guarantees high production standards and qualified technical assistance on an international scale.
FAQ
- What is the difference between a voltage dip and an interruption?
According to standard IEC EN 50160, a voltage dip is a temporary reduction of voltage between 90% and 5% of nominal voltage, while an interruption occurs when voltage falls below 5% on all phases. Both can cause production stoppages but require different technical solutions. - How does Oxygen Zero by Ortea Next work?
Oxygen Zero uses technology based on supercapacitors that instantly detects the voltage drop and restores the nominal level in a few milliseconds, without using traditional batteries. This ensures lower maintenance costs and greater reliability over time. - In which industrial sectors is it advisable to install Oxygen Zero?
It is particularly recommended in all sectors with continuous or highly automated processes such as plastics, packaging, automotive, pharmaceutical, food and textiles, where even a brief interruption can compromise the entire production cycle and cause significant economic losses.
