CHALLENGE
TSABASSIS, part of the PALIRIA Group and a rapidly growing frozen food production unit located in Argos, faced significant challenges due to high energy costs. These costs led to a notable increase in production expenses and a reduction in the company’s competitiveness. Additionally, the limited capacity of power transformers and power cables made it difficult to expand the electrical infrastructure without incurring very high costs. Current and voltage harmonics, along with resonance effects on critical electrical loads, negatively affected operational reliability, while frequent voltage sags from the grid caused unwanted stoppages and loss of production time and raw materials. The company sought an integrated solution with guaranteed energy savings and the ability to resolve the aforementioned technical issues.

SOLUTION
SENERQON GROUP designed and implemented a comprehensive energy upgrade project for TSABASSIS, with a guaranteed electric energy savings target, leveraging modern Artificial Intelligence (AI) techniques. The aim of the project was to maximize energy savings, significantly increase the capacity of the electrical installation, drastically suppress current and voltage harmonics to improve operational reliability, and stabilize voltage during intense sags to avoid production stoppages.

Key actions included:

Detailed measurements of all critical electrical parameters (voltage, current, active and reactive power), as well as harmonic analysis up to the 35th order and detection of transient phenomena, using advanced technology equipment such as the PQ-BOX 200 by Eberle.

Collection and analysis of theoretical data from the installation (single-line diagrams, transformer specifications, motors, inverters, etc.), utilizing Multi-Layer Perceptron-type neural networks.

Scientific study based on the above data, including simulations of the installation’s operation and detection of malfunctions using advanced AI algorithms such as XGBoost, trained through finite element simulations.

Design and implementation of specialized, customized interventions tailored to the specific requirements of the TSABASSIS plant, including:

RITTAL panels customized to the factory’s operational needs.

Siemens PLC controllers with custom software developed by SENERQON for dynamic management of interventions, based on load diversity.

Specialized power electronics, coils, and capacitors (from Siemens, ABB, Schneider, Merus Power), custom-designed by SENERQON based on simulation results. These are not off-the-shelf products but exclusive solutions specifically engineered for TSABASSIS to ensure optimal performance for the facility’s unique conditions.

Installation of these solutions was carried out without any disruption to the production process. Pre-installation (wiring, panel placements, etc.) was performed during normal operating hours, while final connections were made during scheduled maintenance.

RESULTS & BENEFITS
QUANTITATIVE BENEFITS
13.2% confirmed energy savings, far exceeding the contractually guaranteed 9.7%.

Energy consumption measurements with and without the interventions were conducted under consistent production conditions from project commissioning in November 2023 onward. Multiple production scenarios were tested to ensure high reliability of the savings assessment.

TECHNICAL & OPERATIONAL BENEFITS
25% reduction in apparent power, increasing available capacity and avoiding future equipment investments.

Approximately 60% reduction in maintenance costs due to decreased current stress and related thermal wear on electrical components.

Reduction of current and voltage harmonics to below 5% and 2% respectively (from 43% and 5.6% before intervention).

Optimization of equipment performance, including VFDs, motors, transformers, and cables.

Voltage stabilization within the factory’s internal grid to nominal levels—even during sags lasting up to 2 seconds—resulting in improved reliability and fewer unplanned operational shutdowns.

QUALITATIVE BENEFITS
Minimized harmonics and reactive currents, enhancing equipment longevity.

25% increase in available apparent power, allowing for future expansion without additional equipment.

Improved voltage quality and elimination of operation disruptions, boosting production stability.

FINANCIAL BENEFITS
13.2% cost savings on electricity.

Payback period: only 1.8 years, demonstrating rapid ROI.

Significant maintenance cost reduction (60%).

Up to 25% reduction in future expansion costs, fewer production stoppages (minimizing loss of time and raw materials), and substantial improvement in the company’s competitiveness.

WHY THIS PROJECT STANDS OUT
Includes a contractually guaranteed savings commitment, with actual savings significantly exceeding the guaranteed level.

Offers measurable, sustainable, and documented technical and financial results.

Delivers multiple operational and financial benefits, boosting the company’s competitive edge.

Utilizes cutting-edge AI modeling for simulating the electrical system, designing customized interventions, and managing variable characteristics—pioneering practices in the field.

Employs specialized engineering solutions, not generic commercial products.

Demonstrates a powerful synergy between innovation and guaranteed business value.