Project Overview
A food manufacturing facility in Manzanillo required a reliable backup power system to protect critical processes including refrigeration, freezing, production lines and auxiliary services.
Orange Power Systems engineered and integrated an automatic low-voltage synchronization and power distribution system designed to coordinate the facility's utility sources and backup generator while maintaining operational continuity during utility disturbances.
The project combined power infrastructure, automation, protection and centralized monitoring into a single integrated system.
System Overview
| Feature | Detail |
|---|---|
| Location | Manzanillo, Colima, Mexico |
| Industry | Food manufacturing |
| Application | Backup power & synchronization |
| Main bus | 6,000 A |
| Voltage | 480 VAC |
| Backup generation | 1 × 2,500 kVA |
| Utility incomers | 3 × 1,500 kVA |
| Short-circuit rating | 100 kA bus rating |
The Challenge
Food processing operations depend heavily on continuous refrigeration and freezing. A prolonged power interruption can affect production, stored product and essential plant services.
The facility required a system capable of:
- Maintaining power availability for critical processes
- Automatically coordinating multiple utility incomers and backup generation
- Providing safe electrical transitions during utility disturbances
- Centralizing system supervision and operation
- Supporting future expansion of the electrical system
The Solution
Orange Power Systems engineered and integrated a 6,000 A low-voltage synchronization and power distribution system combining utility sources, backup generation, protection and control.
The solution included:
- Main switchgear integration
- Automatic generator synchronization
- Utility and generator source coordination
- Protection and electrical interlocking
- Centralized HMI monitoring and control
- Automatic operating sequences
- Testing and commissioning
How the System Operates
Under normal conditions, the facility operates from the available utility sources.
During a utility disturbance, the control system coordinates the backup generator and electrical sources according to the programmed operating sequence, allowing critical plant loads to remain supported while maintaining electrical protection and safe switching conditions.
The centralized interface gives operators visibility of source status, breakers and system operation.
Scope of Work
- Electrical and control engineering
- Switchgear integration
- Synchronization and control architecture
- Protection and interlocking logic
- HMI integration
- Functional testing
- On-site commissioning and validation
Results
- Critical process continuity — Backup power protects refrigeration, freezing and production-related loads.
- Automatic operation — Utility and backup sources operate through coordinated control sequences.
- Centralized visibility — Operators monitor system status from a unified HMI.
- Operational flexibility — The architecture allows safe operation and future system expansion.
