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Reliable UPS Power Protection for Critical Manufacturing Equipment: A Case Study

Industrial UPS Upgrade for Furnace and Cooling Tower Systems — Manufacturing Case study

Project Snapshot

Industry:
Electronics and Precision Materials Manufacturing (Rare Earth Magnet Production) Application: UPS replacement for Furnace and Cooling Tower Circulation Pump 

Location:
Laguna, Philippines 

Equipment:
2 units of 20kVA industrial UPS systems with 30-minute battery backup and adaptation transformers

Industrial UPS cooling system upgrade

About the Facility

The plant is part of a global leader in rare earth permanent magnet manufacturing, supplying critical components used in electronic devices, IT products, automotive systems, factory automation, and hard disk drives. Operating multiple plant buildings within a major technology and economic zone, the facility runs continuous manufacturing processes that depend heavily on stable, uninterrupted power.

Within this facility, a Furnace and Cooling Tower Circulation Pump system plays a critical role in production. Any disruption to power at this stage can directly affect output and revenue, making reliable power protection a top priority.

The Challenge: An Unreliable UPS System

The plant’s existing uninterruptible power supply system was frequently switching into Offline or Maintenance Bypass Mode. This meant that critical loads were often connected directly to utility power without any UPS protection at all, leaving the Furnace and Cooling Tower Circulation Pump exposed to voltage fluctuations, power interruptions, and electrical transients.

This vulnerability significantly increased the risk of equipment shutdown, production disruption, and damage to critical manufacturing processes, all of which translated into lower production output and lost revenue.

To make matters more difficult, the plant experienced ongoing challenges getting technical support and after-sales service from its original UPS supplier. Response times were slow, spare parts were hard to source, and reliable maintenance support was essentially unavailable after installation. Repairing the existing system was no longer economically justifiable, since the original manufacturer had become inactive and no distributor or reseller for the brand could be found or reached.

The Solution: A Fuji Electric Industrial UPS System

After a thorough assessment, Fuji Electric recommended installing two units of the Falcon 8500 UPS, each rated at 20kVA, to fully replace the existing setup. The proposed solution was designed to deliver reliable, continuous power protection for the Furnace and Cooling Tower Circulation Pump, supported by 30 minutes of battery backup and properly engineered adaptation transformers.

The engineering process included several key steps:

  • Actual load measurement and load computation
  • Operating current review
  • UPS layout analysis
  • Electrical distribution assessment
  • Transformer adaptation design

The result was a customized power protection solution featuring properly sized 20kVA industrial UPS units, a separate battery rack configuration, transformer adaptation, panel modification, and built-in capacity for future expansion. Every technical detail and business benefit of the proposal was clearly explained to both the engineering team and the decision-makers involved.

Why the Plant Chose Fuji Electric

Even though the initial proposal came in at a higher price point than competing offers, Fuji Electric clearly demonstrated the value and long-term benefits of its solution, ultimately winning the project on merit rather than price alone.

Key factors behind the decision included:

  • Proven industrial UPS technology backed by clear after-sales support, in contrast to the limited support offered by other UPS suppliers in the market
  • A reliable power protection solution explained thoroughly with complete supporting documentation
  • Strong customer relationships, built by engaging closely with internal technical influencers and decision makers
  • A competitive, well-justified technical proposal that earned the trust of both the end user and project influencers
  • Responsive local sales and engineering support, available whenever the customer needed assistance

Key Strengths That Made the Difference

  • Direct principal technical support from factory-trained engineers
  • Principal-backed warranty and spare parts availability, ensuring long-term reliability
  • Strong after-sales and local support through an experienced local engineering and service team
  • Competitive project pricing through a direct relationship with the manufacturer, along with flexible configuration options
  • Global standard quality, fully compliant with internationally certified safety standards

Key Takeaways for Critical Power Protection in Manufacturing

This project highlights how facilities in the electronics and precision manufacturing industry can safeguard critical processes with the right industrial UPS solution. For furnace, cooling tower, and circulation pump applications, dependable power protection can deliver:

  • Continuous protection against voltage fluctuations, power interruptions, and electrical transients
  • Reduced risk of equipment shutdown and production downtime
  • Strong after-sales support and access to spare parts for long-term reliability
  • A scalable power protection setup that can grow alongside future plant expansion

Manufacturers facing an aging or unsupported UPS system can benefit from a similar approach: conduct a full site and load assessment, design a properly engineered replacement solution, and choose a partner that offers dependable long-term technical and after-sales support.