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Coca-Cola – Saudi Arabia

ABOUT THIS PROJECT

Violent Voltage Fluctuation Compromised Coca-Cola’s F&B Production 

 

 

Case Study For Coca-Cola

The F&B industry is challenged by rising costs, competitors and emerging trends. Despite that, F&B has proven to be pandemic-proof, and the industry is expected to hit $342 billion in revenue by the end of 2021. 

 

As a heavily-regulated industry, the production process is crucial to ensure that products sold satisfy the consumer’s taste and comply with safety standards. One of the factors that significantly impact product yield, quality, and rejects is power quality.

 

In this case study, we’ll revisit how Coca-Cola successfully dealt with power quality issues in its Saudi Arabia facility. 

 

 

The Problem

Like any F&B manufacturers, Coca-Cola is dependent on machines for producing, bottling, testing and packaging. The global soft drink maker ensures that every bottle of beverage meets not only the ISO 9001 and ISO 22000 standards but also the company’s quality and food safety policy.

 

However, Coca-Cola’s bottling facility in Saudi Arabia was troubled by a slew of incidents in 2011, which involved frequent equipment breakdown. As the equipment automates the production process, these outages cause unanticipated disruptions and unplanned downtime to the soft drink giant. 

 

Coca-Cola was forced to take immediate mitigative measures, including maintenance and emergency repair works for any malfunctioned equipment. This inevitably leads to unexpected and expensive costs. Also, any equipment breakdown would result in additional labour expenses and production downtime, both leading to negative financial implications. 

 

As a brand with a long-standing reputation, Coca-Cola takes proactive action to identify the root cause that results in machine outages. The F&B giant reached out to Ashley Edison(UK) in search of an effective solution. 

 

Our Diagnosis

Ashley Edison(UK) dispatched a team of highly qualified engineers to the affected facility, conducting a detailed inspection on the equipment, building power infrastructure and the incoming voltage supply from the main grid. 

 

Investigations confirmed the suspicion that Coca-Cola’s production facility is suffering from voltage supply irregularity. The facility is supposed to receive a stable 380V 3-phase AC from the local grid. However, our readings showed voltage fluctuations between 309V to 451V, more than 18% from the nominal value.

 

Voltage fluctuation, which is characterized by frequent bouts of Undervoltage and overvoltage, is damaging to Coca-Cola’s production equipment. For example, an AC motor needs to ramp up the current when powered by a voltage below its nominal rating. This may result in overheating, lifespan reduction and damage to motors. 

 

Likewise, automation modules like PLC, power supply modules and sensors may be sensitive to voltage fluctuations. Voltage sags, even brief ones, can lead to major outages that cause safety hazards. Spikes that exceed the tolerable threshold are likely to damage electronic components in machineries.

 

In addition to the wide input voltage swing, our investigation team also determines that the voltage fluctuation suffered by Coca-Cola is also due to its inherent nature.

 

As incoming isolation transformers are based on fixed calculated values, the entire production facility experiences exceptionally unstable voltage levels, particularly when load varies.

 

 

 

The Ashley Edison (UK) Solution

With the root cause identified, the next step involves implementing mitigative measures to regulate and stabilise the voltage fluctuations. 

 

Ideally positioned as the industry leader in voltage optimising solutions, Ashley Edison(UK) was awarded the project to resolve this challenge faced by the F&B giant’s operations in the Middle East. 

 

After careful calculations from the Ashley Edison(UK) engineering team, this was the solution:

A 1,000 KVA 3Phase SESL Series Mains Voltage Stabiliser to be installed at the production facility. 

 

Ashley Edison(UK) SESL 3 Phase Automatic Voltage Stabiliser

Model: SESL-1000H-3P-S20

 

  • Servo Electronic Digitally Enhanced Design
  • Stepless & Automatic Voltage Regulation (± 0.5% output voltage accuracy)
  • Forced-Air Cooling for improved operational efficiency
  • Fast Response Time (<1.5ms)
  • Inbuilt High Overload Capability (10x max current rating for 2 seconds)
  • Independent Phase Balancing & Control: Automatic voltage sensing & precise regulation to ensure individual phase voltages remain stable – regardless of load change or unbalance.
  • Wide input voltage tolerance that compensates low voltage values from 304V, and covers high voltage values up to 456V.
  • Transient Voltage Surge Protection (TVSS) protects critical loads against harmful high energy surges, transients and spikes.
  • Class II SPD – Lightning Surge Protection
  • Endurable NEMA 1 Style Enclosure – BS EN 60529 
  • AquaStop – Protective PCB coating against moisture ingress

 

The SESL Series is trusted as the key to solving Coca-Cola’s voltage fluctuation issues in Saudi Arabia. The unit is backed by a 3-years warranty, with all parts covered. This proposal was eventually accepted and installed to safeguard Coca-Cola’s facility from future voltage anomalies. 

 

Ashley Edison(UK) SESL 3 Phase AC Automatic Voltage Stabilizer

 

Results 

Once the SESL automatic voltage stabiliser was installed and commissioned, the production facility recorded stable voltage at the nominal 380V level. Thanks to the mains voltage stabiliser, fluctuations on the voltage line is reduced from 18% to a precision level of under ±0.5% accuracy. This results in an extremely stable and constant voltage that powers the entire production facility.

 

The SESL AC automatic voltage stabiliser is designed for reliability. To date, no warranty calls have been activated by Coca-Cola and the installed mains voltage stabiliser remains essential equipment in the facility. 

 

A stable and accurate voltage level also means that the production facility is operating at the level of efficiency as it should be. Bottles of soft drinks are produced and shipped as per schedule.

 

For Coca-Cola’s stakeholders, installing the SESL AC automatic voltage stabiliser is a sound financial decision. As beverage production resumes without disruption, so does profitability as the soft drinks make their way to consumers. 

 

Conclusion

Voltage quality is an often overlooked variable in F&B manufacturing. This case study demonstrates the importance of a clean, fluctuation-free power supply and its impact on productivity, profitability and consumer satisfaction. 

 

With a wealth of over 40 years of experience solving voltage quality issues that plague many organisations, Ashley Edison(UK) continues to inspire absolute voltage optimisation across the F&B industry. 

Drop us an email at [email protected] to learn how you can benefit from the Ashley Edison(UK) range of voltage control solutions.

 

For more case studies on how one of the largest testing and certification providers in the world, TÜV SÜD, has also adopted these industry techniques – read about their project here.

coca cola
client
Coca-Cola
PROJECT COMPLETION
2011
EQUIPMENT SIZE
AVR | 1,000 KVA
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Stay Safe With Greater Protection

As safety is our utmost priority, Ashley Edison prepares for every scenario possible
—taking the puzzle out of your protection.

Designed And Engineered With Safety In Mind

We leave nothing to chance when it comes to larger capacity units (≥400KVA). By installing high-quality protective acrylic shields in front of live parts, we ensure the safety of your personnel at all times. For enhanced protection during installation, all distances between uninsulated metal parts, busbars, and cable sizes are compliant with IEC61439-1 and IEC 61439-2 guidelines.

Outfitted with fireproof cable trunking, this protective solution safeguards against long fire exposure even in hazardous areas and explosive atmospheres—providing maximum safety for mission critical applications.

Fuss-Free Installation. Seamless Operations.

To ensure ease of installation, Ashley Edison addresses the concerns of contractors and installers by keeping it simple.

Internal-AVR

ALL TERMINATION POINTS ARE MANUFACTURED FOR EASY ACCESS

We keep the installation process simple and streamlined by allowing sufficient working space for installers. Taking the nut and bolt intrusions into consideration, we ensure that the distance between the uninsulated metal parts, the busbars, and cable sizes are compliant with IEC61439-1 and IEC 61439-2 guidelines.

 

Even in units with larger capacities, all busbar terminals are clearly marked out, and well positioned in line for easy identification of individual input and output terminations. Installation of these terminations are similar to those practised in high voltage transformers.

Easy Maintenance

Annual Ocular Maintenance
Visual Inspection 230
#1

Conduct Visual Inspection On Voltmeter:

Ensure reading is set to your desired set output voltage value (e.g. 230V).

LED Status
#2

Ensure LED Status Indicators are at “Normal”.

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#3

Visual Observation Of Variable Transformer Surface:

Use airbrush for dusty environments if necessary.

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#4

Visual observation if carbon brush is not worn out.

Moving Motor
#5

Conduct visual inspection to check variable transformers are all regulating (moving).

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Accuracy. Beyond Imagination.

The digitally enhanced Ashley Edison MBB Card ensures pinpoint voltage stabilisation against the most erratic anomalies, allowing you to protect precious uptime, effortlessly. Harnessing ultra precision capabilities to produce some of the tightest output voltage tolerance available in the industry, the Ashley Edison MBB Card delivers ±0.5% voltage accuracy, enabling your load equipment to enjoy optimal voltage supplies, regardless of load change in your electrical system.

Expert Digital Control

Utilising the advantageous measurements of true RMS, the Ashley Edison MBB Card’s reads both perfect, sinusoidal waves, as well as complex, distorted non sinusoidal waves—up to 0.1V accuracy. Coupled with lightning fast response time of 1.5ms, this expert digital control feature equips your load with total voltage protection that is precise, continuous and ultra responsive.

AE Digital Control Display_230v

Universal Presettable Function

The Universal Presettable Function onboard the Ashley Edison MBB Card allows seamless control of your desired output voltage value on all 3 Phases—with just a touch of a button. This multifunctional feature enables each AVR to fully operate with just 1 card, instead of separate cards for each individual phase. Fitted LED Output Voltmeter Display and Alert Indicator better facilitates easy status monitoring while performing maintenance on your AVR.

AE MBB Card

Microcontroller Unit (MCU)

MicroController Unit (MCU) helps you to deliver high speed and reliable efficiency in the AVR’s operations with less heat generation and reduced power consumption. Used in Supercomputers, Surface Mount Technology (SMT) allows components in the Ashley Edison MBB Card to be aligned closer together, creating a more compact and lightweight end product. Additional safety wire-to-board feature establishes fail-proof connectivity between circuits—so you can work safely on your AVR.