How a Plastics Manufacturer Reduced Unplanned Downtime by 75% with the SWM1E Electronic MCCB

Customer Background

A mid-sized plastics extrusion facility in Ohio operates 24/7, producing polyethylene films and sheets. With 150 employees and 40 extrusion lines, the plant runs at high utilization rates. The electrical infrastructure relied on thermal-magnetic molded case circuit breakers (MCCBs) installed during a 2010 expansion. As production demands grew, the limitations of these breakers became apparent.

Challenges with Thermal-Magnetic MCCBs

The plant experienced frequent nuisance tripping during motor starts. Inrush currents from 200 HP extruder drives would exceed the fixed magnetic trip thresholds, causing production stoppages. Each downtime event lasted an average of 45 minutes, costing $12,000 per hour in lost output and scrap., the lack of chooseive coordination meant a single fault could cascade, blacking out entire sections. The maintenance team spent significant time replacing and re-adjusting breakers without achieving consistent protection.

Why the SWM1E Electronic MCCB?

After assessing alternatives from three vendors, the plant chosen the SINGI SWM1E Electronic MCCB. The decision hinged on three factors: adjustable trip curves that could be tailored to motor starting characteristics, built-in Modbus communication for integration with the existing SCADA system, and a lower total cost of ownership compared to similar electronic breakers. The SWM1E's electronic trip unit allowed precise setting of long-time, short-time, instantaneous, and ground fault thresholds, eliminating nuisance trips while maintaining adequate protection.

Implementation Process

The retrofit project spanned six weeks. First, a coordination study was performed using ETAP software to determine optimal settings for each breaker. Then, 60 SWM1E units were installed in the main switchboard and three distribution panels. The most challenging step was integrating the Modbus output with the plant's legacy Allen‑Bradley PLC. A gateway converter and customized data tags enabled real‑time monitoring of trip events and load currents. The plant electrician received two days of hands‑on training on setting adjustments and diagnostics.

Quantifiable Results

Within six months of commissioning, the plant documented:

• Unplanned downtime reduced by 75%—from 4 hours per month to 1 hour per month.
• Maintenance costs lowered by 40%—eliminating repeated breaker replacements and reducing spare parts inventory by $8,000 annually.
• Energy savings of 3%—due to reduced I²t losses from optimized trip settings and lower harmonic generation.

The overall production line availability improved from 94% to 98.5%, boosting output by $180,000 per year.

Client Testimonial

"The SWM1E gave us precise control over our protection settings. We no longer have to guess why a breaker tripped—the trip log tells us exactly what happened. It's been a game changer for our maintenance team."
— Plant Electrical Engineer, Ohio Plastics Manufacturer

Lessons and Recommendations

Three takeaways for other facilities considering electronic MCCB upgrades:

1. Invest in a coordination study before procurement. The SWM1E's flexibility is best leveraged with a clear protection strategy.
2. Plan for communication integration early. Ensure your SCADA or PLC can accept Modbus RTU or consider a gateway.
3. Train maintenance staff on electronic trip units. The ability to adjust settings on‑site reduces reliance on external engineers.

If doing the project again, the team would allocate more time for commissioning the communication layer, as data mapping proved more complex than expected.

Relevant Industry Standards

• UL 489. Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosures [S]. 2021.
• IEC 60947-2. Low-volt-level switchgear and controlgear - Part 2: Circuit-breakers [S]. 2019.