Case Study: High-Efficiency Transformer Solution for Industrial Power Stability
Client: Leading Automotive Components Manufacturer
Location: India (Confidential)
Project Year: 2024
Sector: Transformer Manufacturing / Industrial Power Solutions
A leading automotive components manufacturer faced voltage instability and energy inefficiencies, impacting the reliability of its production lines. The client required a high-performance, energy-efficient transformer to stabilise the power supply, reduce losses, and ensure long-term operational efficiency.
Mahati Electrics was chosen to design, manufacture, and deliver a high-efficiency industrial transformer that meets global IEC standards, enhances energy savings, and supports the client's expansion into export markets.
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Challenges & Requirements
The client’s growing production demands required a transformer solution that addressed:
Voltage fluctuations impacting precision manufacturing equipment.
High energy losses leading to increased operational costs.
Need for a low-maintenance, long-lifespan transformer to reduce downtime.
Compliance with IEC & ISO standards to enable export market certification.
The existing transformers in the facility were outdated, operating at low efficiency and contributing to heat losses, further affecting productivity.
Mahati’s Approach & Solution
Mahati custom-designed and manufactured a high-efficiency 2500 kVA oil-immersed power transformer, tailored for the client’s industrial power needs.
Solution Highlights:
Energy-efficient core design, reducing iron losses by up to 30%.
Low-loss windings, improving transformer efficiency and reducing operating costs.
Enhanced cooling system, ensuring optimal temperature control for a prolonged lifespan.
IEC 60076 & BIS-compliant, meeting international quality and safety standards.
Hermetically sealed design, eliminating maintenance requirements for oil preservation.
The transformer was designed for export-ready compliance, ensuring future scalability as the client expanded its global manufacturing footprint.
Implementation & Execution
The project was executed in a structured timeline, ensuring seamless installation and operational transition:
Phase 1 – Engineering & Design:
Conducted load analysis to determine optimal transformer specifications.
Designed a low-loss, high-efficiency core structure for long-term savings.
Phase 2 – Manufacturing & Quality Assurance:
Produced using ISO 9001-certified processes, ensuring precision engineering.
Conducted routine tests & type tests as per IEC standards, including:
Short-circuit withstand tests
Temperature rise tests
Partial discharge measurements
Phase 3 – Installation & Commissioning:
The transformer was installed with minimal production downtime.
Live testing ensured voltage stability and optimal efficiency before full operation.
Mahati’s precision manufacturing and quality assurance processes ensured a zero-defect product delivery, reinforcing reliability.
Results & Impact
Voltage stability improved by 97%, ensuring uninterrupted operations.
Energy losses reduced by 30%, leading to significant cost savings.
Transformer lifespan extended to 25+ years with advanced insulation & cooling.
Compliance with IEC 60076 & BIS standards, supporting future export certification.
Zero maintenance required due to hermetically sealed design.
The client reported a noticeable improvement in power quality, leading to higher productivity and reduced equipment wear and tear.
Future Outlook & Scalability
The project demonstrated Mahati’s expertise in manufacturing high-efficiency transformers for industrial applications. The scalable transformer design ensures the client can expand operations without requiring further major electrical infrastructure upgrades.
This successful implementation positions Mahati as a preferred supplier for industrial transformers in both domestic and international markets, supporting the client’s long-term growth.
Why Mahati?
Mahati’s industry-leading expertise in transformer manufacturing made it the ideal partner for this project:
Bespoke transformer solutions, designed for efficiency and longevity.
Global compliance with IEC & BIS standards, ensuring export readiness.
State-of-the-art manufacturing processes, delivering precision and reliability.
Seamless project execution with minimal operational disruptions.
By delivering a high-performance, low-maintenance transformer, Mahati provided the client with a future-proof power solution that enhances efficiency and long-term sustainability.