Case Studies

Tank Street, Brisbane CBD

A Brisbane contractor was asked by their client to investigate ways to reduce the cost of their electricity expenditure. The building is a typical multi-storey commercial building on Tank Street which houses three government departments. The contractor teamed up with Fuseco and the results were impressive.

Product: Sinexcel SVG

Injection moulding business in Brisbane

An injection moulding business based in Brisbane engaged Fuseco to investigate ways to reduce the cost of their electricity expenditure. Their operation is a good example of a dynamic medium sized engineering facility. After conducting a site visit and analysing their power quality, it became apparent that correcting their power factor would yield significant savings. A saving of over $1,000 per month was achieved!

Product: Sinexcel SVG

Koala Cherries

Koala Cherries is based in Yarck, two hours north east of Melbourne. Owned and operated by cousins Michael and Simon Rouget, this 3rd generation cherry growing, packing and marketing business operates across three growing regions and farms more than 200ha of cherries. Koala Cherries approached Fuseco requesting some solutions for the power quality issues they were experiencing, in particular low power factor. The Sinexcel SVG-400-4-4l-RL cabinet solution was selected.

Product: Sinexcel SVG

Peel AG

Peel AG is a chicken farm located near Winchelsea, Victoria. The management reached out to Fuseco to conduct a power quality site audit as they suspected that the operation was experiencing inefficiencies and the annual power costs were perceived to be quite high. They had recently installed some solar panels and wanted to know if there was anything else that could be done to achieve optimum efficiency and minimal costs. A Sinexcel SVG solution was the perfect solution.....

Product: Sinexcel SVG

CR Surfacing Laboratories

Since 1976, CR Surfacing have been Australia's premium & most innovative prescription lens manufacturer. TG Pell electrical reached out to Fuseco on behalf of CRS to assist with upgrading their PFC capacity to cater for the expansion of the site. After careful analysis, it was decided that a 2nd Sinexcel 100kVAr wall mounted unit was to be added to the first unit which was installed a couple years earlier.

Product: Sinexcel SVG

9 Mile

Located near Tynong in Victoria, 9 Mile is one of Australia's premier apple growers & suppliers with the largest and most advanced processing facility in the southern hemisphere. The electrical contractor Acculec reached out to Fuseco for assistance to achieve an energy cost saving for 9 Mile's state of the art facility. The installation of a 500kVAr Sinexcel SVG PFC system yielded incredible results!

Product: Sinexcel SVG


Located near Derrimut, Melbourne is the bottling & distribution facility of the timeless classic brand Campari. The electrical engineering team on site suspected that they had poor power factor, a fact that was confirmed once they conducted their power quality measurements. They calculated that a 350kVAr solution would be required and reached out to Fuseco for advice. The installation of a Sinexcel 350kVAr SVG system transformed their electrical environment.

Product: Sinexcel SVG

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Power Factor is a measure of how effectively incoming power is used in your electrical system and is defined as the ratio of Real (working) power to Apparent (total) power.

Real Power (KW) is the power that actually powers the equipment and performs useful, productive work. It is also called Actual Power, Active Power or Working Power.

Reactive Power (KVAR) is the power required by some equipment (eg. transformers, motors and relays) to produce a magnetic field to enable real work to be done. It’s necessary to operate certain equipment but you don’t see any result for its use.

Apparent Power (KVA) is the vector sum of Real Power (KW) and Reactive Power (KVAR) and is the total power supplied through the power mains that is required to produce the relevant amount of real power for the load. Let’s look at a simple analogy in order to better understand these terms. 

Let’s say you’ve ordered a glass of your favourite beer. The thirst quenching portion of your beer is represented by Real Power (KW). Unfortunately, along with your ale comes a little bit of foam that doesn’t quench your thirst, represented by Reactive Power (KVAR). The total contents of your glass (KVA) is this summation of KW (the beer) and KVAR (the foam). The power factor is the ratio between Real Power and Apparent Power. It’s expressed as a value between -1 and 1 and can be either inductive (lagging) or capacitive (leading). If the power factor is 1, then all of the power supplied is being used for productive work and this is called ‘unity’.

Therefore, for a given power supply (KVA):

  • The more foam you have (the higher the percentage of KVAR), the lower your ratio of KW (beer) to KVA (beer plus foam). Thus, the poorer your power factor.
  • The less foam you have (the lower the percentage of KVAR), the higher your ratio of KW (beer) to KVA (beer plus foam) and the better your power factor. As your foam (or KVAR) approaches zero, your power factor approaches 1.0 (unity).

A power factor of -0.7 for example, indicates that only 70% of power supplied to your business is being used effectively and 30% is being wasted. The wasted power is the Reactive power (the foam in the previous example). Most loads are inductive in nature, which means the power factor will typically be less than unity. The further the power factor is from unity, the greater the apparent power drawn and therefore, the greater the current draw for the system.

The increased current may require an increase in the size of your transformers and installation power wiring. Increased current also results in increased heat which affects the longevity and lifespan of an electrical system. This can add a great deal of cost to the installation and may also limit the expansion of a plant.

It’s important because you may be paying for reactive power (foam) that you cannot use to power equipment. If you can reduce the foam, you can get more ‘beer for your buck’. Improving the power factor results in less current being drawn, therefore less electricity costs, less heat and greater longevity of the electrical system.

Many power suppliers charge for the base load (kW) and a maximum demand tariff. If this maximum demand tariff is measured in kVA, then improving the power factor reduces the kVA of

the installation, thus reduces the maximum demand tariff and thereby reducing your power costs.

It is actually a network regulation that customers maintain a specific minimum power factor (values depend on your region). Utility companies may charge customers a penalty on top of consumption charges when customer power factor is less than a determined value.

Poor Power Factor can be improved by installing Power Factor Correction (PFC) equipment. Traditional solutions incorporate banks of capacitors that work as silent reactive power ‘generators’, often housed in a metal cabinet similar to the one that houses your electrical switchboard. Fuseco offers the latest generation of advanced performance PFC solutions that do not need a capacitor bank and offer many advantages due to their compact and modular configuration.

An electrical load with a poor power factor draws more current than a load with an improved power factor for the same amount of useful power transferred and can put unnecessary strain on the electricity distribution network. By improving your power factor, you can reduce your electricity bills through lower monthly demand and capacity charges. Typically payback periods for power factor correction are between 1-3 years. Given the life expectancy of power factor correction equipment and the potential savings, it can be a very worthwhile investment. Poor power factor may cause power losses and voltage drops, which can contribute to overheating and failure of motors and other equipment. If your electrical system is near capacity, installation of power factor correction equipment may help avoid costly infrastructure upgrades by lowering the existing electrical demand on your system and improving efficiency stability.

Due to the operational temperature and safety requirements applicable to capacitor banks, traditional PFC systems are constructed as a separate, stand-alone assembly or in self-contained spaces within the overall construction of the main switch board. This results in the common situation where PFC systems occupy a large space, often taking up valuable floor space in switch rooms.

Sinexcel have applied new generation thinking and innovative design principles to create a new generation of PFC solutions that do not use a switched capacitor bank system. This has redefined what is possible from a cost vs performance vs space perspective.

Sinexcel SVG are a modular design that are available in wall-mount, rack-mount and rack/cabinet configurations. This flexibility gives engineers multiple options to cater for all situations and ultimately save valuable space and floor real-estate.

Compensating kVAr Capability vs Space

  • Up to 100kVAr capability from a wall-mount solution
  • Up to 100kVAr capability from a single rack-mount module
  • Up to 400kVAr capability from a single standard cabinet solution
  • Up to 600kVAr capability from a single ‘drawer-type’ cabinet solution


Power Factor is a measure of how effectively incoming power is used in your electrical system (energy efficiency) and is defined as the ratio of Real (working) power to Apparent (total) power. By improving your power factor, you can reduce your electricity costs. Fuseco is Australia's leading experts in Power Factor Correction. Contact us for a free site appraisal and no obligation assessment.
By installing Power Factor Correction equipment, you will be able to improve your Power Factor and reduce your Peak kVA Demand Tariff and this will result in significant savings in your electricity costs. Fuseco is Australia's leading experts in Power Factor Correction. Contact us for a free site appraisal and no obligation assessment.
The Electricity Utilities are changing the way they billing you. Improving your power factor can result in considerable savings on your power bills. Fuseco is Australia's leading experts in Power Factor Correction. Contact us for a free site appraisal and no obligation assessment.

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From the moment the AHF and SVG units were turned on our power factor issues were a thing of the past. At both sites our PF is now 0.99 on all phases all the time, the units react instantaneously to our fluctuating load and power factor and the result has been an excellent return on investment.

Brad Kilner


The PFC units are now installed and running. They are doing a great job at maintaining a constant PF of 0.99 across all phases. Great product and excellent support from both of you. Very pleased doing business with you. Your help has been much appreciated.

Darren Brownscombe


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