Projects
Smurfit Kappa

Transformer replacement project

Established in 1934 in Dublin, Ireland, Smurfit Kappa has evolved into a leading global provider of paper-based packaging solutions. The company specialises in designing, manufacturing, and supplying a diverse range of products, including corrugated packaging, solid board, folding cartons, and Bag-in-Box solutions. These offerings cater to various industries, such as food and beverage, consumer goods, and industrial sectors, emphasising sustainability by producing 100% renewable products.

Smurfit Kappa's operations are vertically integrated, encompassing the entire production process from raw material sourcing to the final packaging. This integration ensures consistency and quality across their product lines. The company's commitment to sustainability is evident in its efforts to help customers reduce their environmental footprint through innovative, eco-friendly packaging solutions.

In the UK, Smurfit Kappa is a major player in the paper-based packaging industry, operating numerous facilities across the country. Smurfit Kappa UK focuses heavily on innovation and sustainability. Its facilities are equipped with advanced technology for custom packaging design, helping businesses reduce waste and improve supply chain efficiency. The company also offers closed-loop recycling services, collecting used cardboard and paper to be reprocessed into new packaging, supporting a circular economy. We supplied transformers to two of their facilities.

Following an energy efficiency review, their Stalybridge production site was identified as being able to benefit from voltage adjustment. With the HV transformer owned by the company, the decision was made to replace the existing transformer with a modern super low-loss amorphous unit that would provide savings through reduced transformer losses as well as reduced supply voltage to the site.

The installation of the Wilson e2 Super Low Loss Amorphous® Transformer, combined with a 5.9% voltage reduction, has significantly reduced the energy wasted at the Stalybridge site. The projected annual savings (based on £0.09/kWh) are in excess of £10,500 per annum. The payback on the total investment, including transformer purchase and installation, will be achieved in under three years.

Sector	Industrial & Manufacturing
End User	Smurfit Kappa
Location	Stalybridge and Glasgow
Scope of Work	1MVA Wilson T2 Ecotran® Distribution Transformer 1MVA Wilson e2 Super Low Loss Amorphous® Transformer

99176 kWh

annual savings

10500

annual payback

based on 9p/kWh

The Scope

Following the installation of a Super Low Loss Transformer at the site, an energy efficiency and power quality survey was conducted to quantify the energy savings. This report presents the recorded Power before and after the new transformer was installed. Many aspects of power quality and energy efficiency are interrelated, so due diligence requires a comprehensive assessment to represent the best interests of the end customer. Power analysing monitoring equipment was connected to the main incoming LV supply and left in situ for 7 days. The data shows the before and after installation readings.

Our Findings

The measurements show that installing the Wilson e2 Super Low loss Amorphous Transformer, combined with a 5.9% voltage reduction, has reduced the kWh used. The measurements taken before installation and those with the Wilson e2 transformer on tap 3 show a 3.5% reduction in kWh. On a projected usage of 2,861,652kWh before installation, the savings are estimated to be 99,176kWh p.a. The kWh reduction can be exhibited long-term using the electricity supplier’s half-hourly averaged value data. Subsequently, the reduction in voltage has also improved the site's power factor.

Replacement with Wilson Amorphous Transformer

Payback Calculator

Europe’s most efficient distribution transformer

Upgrading to Wilson e4 Ultimate Low Loss Amorphous® Transformer provides you with substantial carbon, energy and financial savings. Use our payback calculator to find our potential savings.

Your Exisiting Transformer Rating (kVA)