PROJECT OVERVIEW

The multinational company CAMPARI S.p.A., through its facility in Volos, sought to upgrade its electrical infrastructure, enhancing both the sustainability and resilience of its production. The goal was to achieve significant energy savings, reduce current and voltage harmonics, increase the efficiency of transformers and motors, and ensure higher power reserve — all without disrupting production operations.

SOLUTION

SENERQON GROUP designed and implemented a fully customized energy optimization project using advanced techniques for data collection, measurements, and simulation of the electrical installation's operation. The process included:
- Measurements of key parameters (current, voltage, power, etc.) and harmonic distortion up to the 35th order, as well as transient phenomena using PQ-BOX 200 portable devices. The results were analyzed using Artificial Intelligence models (Multi-Layer Perceptron Neural Networks).
- Simulation of the entire electrical system and the interactions between loads. Advanced AI algorithms (MLP and XGBoost) trained on finite element simulations (FEM) were applied.
- Design and installation of tailored interventions adapted to the operational conditions of CAMPARI’s Volos facility, including:
• Custom electrical panels by RITTAL.
• Siemens PLCs controlling the intervention logic, supported by custom software developed with AI models based on system simulations.
• Custom power electronics, inductors, and capacitors by Siemens, ABB, Schneider Electric, and Merus Power, engineered specifically for the site using simulation results. These were not off-the-shelf components but customized solutions optimized for this installation.
- Installation of the customized solutions in parallel with the existing loads, commissioning, and tuning of the control software, without interrupting production. The final wiring was completed during a scheduled maintenance shutdown, minimizing downtime.

RESULTS & BENEFITS

- 13.46% energy savings, exceeding the guaranteed target of 9.6%. Savings were verified through comparative consumption measurements under stable production conditions across various scenarios from November 2024 onwards.
- Equivalent 13.46% cost savings on electricity bills, as all charges are proportional to consumption.
- Project payback time: 2.17 years.
- Approx. 25% increase in available power reserve, reducing the need for future investments in transformers, panels, or cabling in case of future plant expansions.
- 72% reduction in electrical equipment maintenance costs.
- Significant reduction in harmonics and transients, improving overall power stability.

WHY THIS PROJECT STANDS OUT

- Achieved energy savings well beyond the guaranteed levels.
- Multiple additional benefits that enhance competitiveness.
- Tangible, verifiable, and sustainable results.
- Fully implemented industrial project — not a pilot or study.
- Use of advanced AI for simulation, design, and adaptive control.
- Custom-engineered solutions — not generic components.
- High complexity execution without production interruption.
- CAMAPRI demonstrates leadership in energy transition through its collaboration with SENERQON.
- The project serves as a model of industry–innovation synergy with direct environmental and business impact.