Case Study: Enhancing Power Distribution for a Large-Scale Manufacturing Facility
Client: Leading Automotive Components Manufacturer
Location: India (Confidential)
Project Year: 2024
Sector: Power Distribution / Industrial Solutions
A leading automotive components manufacturer required a high-reliability power distribution system to support its growing production capacity. Fluctuations in power supply were affecting operational efficiency, leading to potential downtimes. Mahati Industries was chosen to design, manufacture, and commission a fully optimised power distribution solution, ensuring stable power delivery, enhanced energy efficiency, and compliance with international safety standards.
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Challenges and Requirements
The client’s expansion required a modernised power distribution network that could support:
Eliminating power fluctuations impacting precision manufacturing equipment.
Ensuring IEC & ISO compliance for future global export certifications.
Reducing energy losses & optimising power consumption for cost efficiency.
Minimising maintenance downtime, with scalable solutions for future capacity expansions.
With an increasing demand for EV components, the client required a low-maintenance yet highly efficient electrical distribution infrastructure to support continuous production.
Mahati’s Approach & Solution
Mahati developed a fully integrated Medium-Voltage (MV) and Low-Voltage (LV) power distribution system optimised for high-reliability operations in industrial manufacturing.
Solution Highlights:
Custom-designed switchgear with adaptive load balancing to stabilise voltage fluctuations.
High-efficiency transformer selection, reducing energy losses by up to 30%.
Advanced circuit protection systems, preventing equipment damage from power surges.
Remote monitoring & predictive maintenance integration, enabling real-time diagnostics.
Seamless integration with existing production lines, ensuring minimal downtime.
By leveraging modular design principles, the system allows for future scalability, supporting increased manufacturing output as the facility expands.
Implementation & Execution
Mahati implemented the project in a phased approach, ensuring zero operational disruptions:
Phase 1 – System Design & Engineering:
Load assessments and feasibility studies were conducted to determine optimal configurations.
Custom switchgear solutions were designed to enhance electrical efficiency.
Phase 2 – Manufacturing & Quality Assurance:
All components were manufactured following ISO 9001-certified processes.
Electrical panels and switchgear underwent rigorous factory acceptance testing (FAT).
Phase 3 – Installation & Commissioning:
Installation was carried out in scheduled production downtimes to avoid disruption.
Full compliance with Indian and international electrical safety standards (IEC, IS, BIS).
Live operational testing and fine-tuning for maximum efficiency.
Mahati’s engineering precision and adherence to global standards ensured flawless implementation, with all systems commissioned on time and within budget.
Results & Impact
Voltage fluctuations reduced by 95%, leading to uninterrupted production.
Energy losses cut by 30%, generating significant cost savings
99.9% system uptime achieved, improving manufacturing efficiency.
Scalable design, supporting an expected 40% production increase over the next 5 years.
IEC and ISO compliance achieved, paving the way for future export market certification.
The client reported significant operational improvements, particularly in reduced maintenance costs and improved power stability – critical factors in ensuring high-quality production.
Future Outlook & Scalability
The project serves as a benchmark for modern industrial power distribution, setting a precedent for similar automotive, steel, and heavy manufacturing facilities looking to upgrade to high-efficiency power systems.
Mahati’s scalable and future-ready design ensures the client can easily expand production without major infrastructure overhauls. The system is export-ready, aligning with global compliance requirements, making it suitable for integration into international facilities.
Why Mahati?
With five decades of expertise in industrial power solutions, Mahati Industries delivered:
Custom-engineered, high-performance power distribution systems.
Industry-leading reliability with best-in-class switchgear and circuit protection.
Seamless integration into existing infrastructure, minimising disruptions.
A scalable, export-compliant solution aligned with global standards.
Mahati positioned the client for long-term success in a competitive global manufacturing landscape by ensuring a future-proof, energy-efficient power system.