A 16-month payback on power factor at Bokomo.
For Bokomo Savoury Foods in Johannesburg, the Augos platform flagged hidden costs from poor power factor. A turnkey correction system eliminated the reactive energy charges and secured a 16-month payback on the R189,000 project. With rising load and tariff changes, the monthly saving has since grown to R19,500, turning an avoidable utility penalty into an escalating financial asset.
- Continuous monitoring flagged reactive-energy costs from poor power factor.
- A turnkey PFC system brought apparent demand (kVA) down near active power (kW).
- The R189,000 project paid back in 16 months.
- Monthly savings have since risen to R19,500 as load and tariffs changed.
Data-driven diagnosis: identifying the waste gap
As part of a long-standing relationship across the Pioneer Foods group, the Augos platform continuously monitors all sites. A routine data review flagged a significant financial opportunity at Bokomo Savoury Foods: substantial penalty costs caused by poor power factor.
The metering data showed the instability clearly. There was a wide gap between active power (kW), the energy actually doing work, and apparent demand (kVA), the total energy supplied. That excess kVA, known as reactive energy, was flowing unnecessarily between the council and the site, adding cost in two ways: the kVA demand was higher than it should have been, and reactive energy charges were being levied on the client.
Turnkey PFC implementation and auditable results
The fix was straightforward and guided by the platform's analysis: install a suitably sized Power Factor Correction system as a full repairs and upgrades solution, designed to bring apparent demand (kVA) down to nearly the level of active power (kW). The results were immediate and auditable:
- Before: a high divergence between power and demand.
- After: the demand line sits almost equal to the power line, confirming a near-perfect power factor. Even with increased load, demand and its associated costs stay controlled.
For food production facilities in South Africa, compliance with utility regulations is central to financial stability. NERSA-regulated tariffs in Johannesburg impose penalties when a site's power factor drops below the mandated threshold. The correction keeps Bokomo compliant, turning an unnecessary utility cost into a fixed, predictable capital asset.
Long-term financial certainty and proven payback
The project's financial metrics provide clear proof of performance:
- Total turnkey project cost: R189,000.
- Initial monthly saving: R12,000.
- Achieved payback period: 16 months.
With increased site load and subsequent tariff changes, the estimated monthly saving has since risen to R19,500. Power factor correction is not merely a cost, it is an escalating financial asset.
What problem did Augos find at Bokomo?
Poor power factor. The metering showed a wide gap between active power (kW) and apparent demand (kVA), which pushed demand higher than it should have been and attracted reactive energy charges from the council.
What is reactive energy, and why does it cost money?
It is the excess apparent power (kVA) beyond the active power (kW) actually doing work. That excess flows unnecessarily between the council and the site, raising kVA demand and attracting reactive energy charges.
How was it fixed?
By installing a suitably sized Power Factor Correction (PFC) system, designed to bring apparent demand (kVA) down to nearly the same level as active power (kW), for a near-perfect power factor.
What was the payback?
Sixteen months on a R189,000 turnkey project, from initial monthly savings of R12,000.
How much is it saving now?
With higher site load and tariff changes, the estimated monthly saving has grown to around R19,500, and rising, turning the correction into an escalating financial asset.
How did Augos spot the problem?
The platform continuously monitors sites across the Pioneer Foods group. A routine data review flagged the divergence between kW and kVA at Bokomo Savoury Foods.
Does power factor correction help with compliance?
Yes. NERSA-regulated tariffs penalise a power factor below the mandated threshold. Correction keeps the site compliant and removes that regulatory risk.
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