Three-phase online UPS, servo stabilizers, and isolation transformers for factories, production lines, and industrial facilities. Keep production running when the grid fails.
Manufacturing facilities face a unique set of power quality challenges that go beyond simple outages. Heavy machinery — motors, drives, compressors, welding equipment — creates voltage sags, transient spikes, and harmonic distortion on the supply line that can silently damage sensitive control electronics.
A voltage sag during a CNC cycle can corrupt a part in progress, requiring expensive rework or scrap. A power cut during a batch process in pharma or food processing can mean discarding the entire batch. PLC and SCADA system crashes caused by power events can take hours to restart properly.
The true cost of a manufacturing power event is far higher than just the downtime — it includes scrap, rework, restart costs, delayed orders, and in some industries, regulatory compliance issues.
A 30-minute power cut during milling: scrap 2 parts (₹15,000 material + ₹8,000 machine time), restart calibration (₹5,000), delayed delivery penalty (₹25,000). Total: ₹53,000 for one event.
A batch interruption forces rejection of an entire 200 kg API batch (₹8 lakh material). Regulatory documentation, deviation report, and re-validation: another ₹3–5 lakh and 2 weeks delay.
Robotic weld line stops: 4 hours restart and recalibration (₹2 lakh/hour production loss). OEM penalty clauses for delayed supply can add ₹10–25 lakh per event.
Complete range of industrial power protection from single-phase UPS for control panels to large three-phase systems for entire production facilities.
The backbone of industrial power protection. True online double conversion UPS for CNC machines, PLCs, robotics, SCADA systems, and process control. Handles high input voltage variation (±20%) and provides clean output regardless of input quality.
Servo stabilizers correct input voltage variations (±50% in extreme cases) to a stable ±1% output. Ideal for areas where voltage fluctuation is the primary concern and battery backup is not required — motors, pumps, lighting circuits, injection moulding machines.
Galvanic isolation between supply and load, eliminating common-mode noise, ground loops, and transient spikes. Essential for sensitive CNC controllers and PLCs in electrically noisy factory environments. Often used in combination with UPS for maximum protection.
Extended runtime battery banks for industrial UPS — internal battery up to 30 minutes, external battery cabinets for 1–4 hours of runtime. For continuous process industries, lithium-ion batteries offer longer life and smaller footprint.
Our industrial UPS solutions are deployed across a wide range of manufacturing sectors throughout India.
UPS for robotic welding lines, PLC-controlled assembly, paint shop process controls, and quality inspection systems. Prevents costly line shutdowns and maintains weld quality.
GMP-compliant UPS for API manufacturing, granulation, compression, coating, and packaging lines. Critical for continuous batch processes and cleanroom HVAC control systems.
Power protection for rapier looms, air-jet looms, embroidery machines, and dyeing control systems. Voltage sags cause pattern defects; UPS prevents costly fabric rejection.
UPS for filling lines, packaging automation, refrigeration controls, and SCADA systems. Food safety regulations require process continuity records — power failures create compliance gaps.
Three-phase online UPS for CNC machining centres, EDM machines, and coordinate measuring machines (CMM). Zero transfer time protects in-progress cuts and prevents coordinate system errors.
Power protection for SMT pick-and-place machines, reflow ovens, AOI systems, and test equipment. Voltage sags cause solder defects; complete outages can destroy partially processed boards.
CNC machines require a three-phase online double conversion UPS with low output THD (less than 5%). CNC controllers and servo drives are sensitive to voltage sags and waveform distortion. We typically recommend sizing the UPS at 150% of the CNC machine's rated kVA to handle startup current and provide adequate safety margin. Many CNC OEMs specify online UPS as a warranty requirement.
Most industrial equipment — CNC machines, PLCs, robots, motors, and process control systems — runs on three-phase power supply. A three-phase UPS provides balanced power to all three phases simultaneously, prevents phase imbalance issues that can damage motors and transformers, and scales efficiently to the 10–500 kVA capacities that manufacturing applications typically require. Single-phase UPS would require three separate units and complex balancing.
Harmonic distortion occurs when heavy electrical loads (VFDs, rectifiers, welding machines) inject non-fundamental frequency currents into the power grid, distorting the voltage waveform. This can overheat transformers, cause nuisance tripping of MCBs, and damage sensitive electronic equipment. Online UPS with active input power factor correction (PFC) absorbs input harmonics and delivers a clean 50 Hz sine wave output — completely isolating downstream equipment from the problem.
For online double conversion UPS, a separate servo stabilizer is not needed — the UPS itself provides tight voltage regulation (typically ±1%). However, a servo stabilizer is useful on the input side of a line-interactive UPS to protect it from extreme voltage swings, or for equipment that doesn't need battery backup but does need voltage regulation (motors, pumps, lighting circuits). We assess each application and recommend the most cost-effective solution.
For an orderly safe shutdown of CNC machines, PLCs, and process control systems, 10–30 minutes of UPS backup is typically sufficient. This allows operators to save work, complete current machine cycles safely, and bring the line down in a controlled manner before DG startup. For continuous process industries (pharma batch, food processing) where restart costs are very high, 60+ minutes may be justified. We calculate the optimal runtime during our free site assessment.
Share your machine list, facility size, and power challenges — we'll prepare a detailed industrial power protection proposal including UPS sizing, stabilizers, and AMC plan.
Every unplanned stoppage has a cost. The right industrial UPS pays for itself in prevented downtime within months. Contact Sukhai UPS Solutions for an industrial power protection assessment.