Restoring visibility, reliability, and control across a complex electrical infrastructure
In mature production environments, years of incremental changes can lead to reduced visibility and increased operational risk. A well-known food & beverage company, with a manufacturing facility in Ploiesti, Romania, was facing recurring electrical issues caused by outdated documentation, system expansion, and limited traceability across its power distribution network.
To address these challenges, a comprehensive power study was required to rebuild system understanding, identify risks, and provide a clear path toward improved reliability and future scalability.
Project Highlights:
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Full electrical power study for legacy production and packaging line
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Real-time load measurements and system inspections
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Creation of updated single-line diagrams
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Identification of overloads, inefficiencies, and protection gaps
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Improved traceability through labeling and system documentation
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Delivery of actionable technical report with visual insights
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Foundation established for future upgrades and compliance
The challenge
Lack of system visibility in an evolving and undocumented electrical network
Over time, the facility’s electrical infrastructure had grown increasingly complex due to multiple expansions and undocumented modifications. As a result, the existing schematics no longer reflected reality, making it difficult to understand load distribution, system capacity, or potential failure points.
Frequent issues such as equipment overloads, power losses, and delayed maintenance interventions began to impact both reliability and operational efficiency. Without accurate data and a clear system overview, identifying root causes or planning improvements became a significant challenge.
Additionally, any assessment had to be conducted without disrupting ongoing production, adding another layer of complexity to the project.
Our approach
A data-driven assessment to rebuild system clarity and enable informed decision-making
Contec approached the project with a structured, field-driven methodology focused on accuracy and practical outcomes.
The process began with on-site data collection and stakeholder discussions to understand both system behavior and operational constraints. Detailed measurements were performed across key load points, capturing real-time data on energy usage and system performance.
Based on this information, the team developed updated single-line diagrams that accurately represented the current electrical infrastructure. Panels and critical components were labeled to improve traceability, while load analysis was carried out to detect imbalances, overloads, and inefficiencies.
All findings were consolidated into a comprehensive report combining technical analysis with clear visual documentation. Close collaboration with site engineers ensured that recommendations were not only technically sound but also feasible within the operational context.
