CASE STUDY
Challenge
A global leader in sustainable packaging was looking to update 50-year-old switchgear installed in its paper mill. While the equipment had not yet failed, it posed a growing reliability and safety risk due to its age and the mill’s hot, dusty and corrosive environment. The switchgear was also obsolete, with limited spare parts available. The company initially assumed full replacement was the only option, but long lead times exceeding a year and the high cost of a rip‑and‑replace project raised concerns about downtime, capital expense and installation complexity.
Solution
The company engaged Wesco to support the switchgear project. Wesco teamed up with one of its world-class supplier partners and performed a site assessment of the paper mill. The assessment revealed that the structures themselves were in good shape, meaning that the existing switchgear was a strong candidate for refurbishment rather than full replacement. Instead of removing and replacing the entire lineup, the team recommended modernizing the internal components with a low voltage breaker retrofit. Leveraging the existing infrastructure eliminated the need for new conduit, cabling and major construction and allowed the work to be completed quicker during planned outages, reducing downtime.
Summary
- Avoided full switchgear replacement
- Saved $700,000
- Achieved faster implementation
- Prevented unplanned downtime
- Improved electrical safety
Results
The low voltage breaker retrofit delivered significant cost savings, faster implementation and enhanced safety for the company. By choosing switchgear modernization over replacement, the company avoided extensive demolition, rewiring and installation labor. The reduced labor and equipment costs together resulted in savings of $700,000 compared to new switchgear. Lead times were also reduced from more than a year to just a few months, speeding time to deployment. The low voltage breaker retrofit with modern breaker technology also improved safety for maintenance personnel by reducing arc flash incident energy. Following the success of the project, the company recognized the approach as a repeatable switchgear modernization strategy and began evaluating similar retrofit opportunities across additional facilities.
