EES Answers All Electrical & Automation Problems

Over the years, we’ve been called into factories, processing plants, and warehouses where downtime, compliance failures, or inefficient systems were costing businesses big money. When others couldn’t fix the problem, we delivered results.

Common Electrical & Automation Problems:

Here are some real-life scenarios we've tackled, the challenges behind them, and the solutions that made the difference.

1. “Our refrigeration plant shuts down randomly, and no one can find the fault. Can you help?”

The Challenge: A food manufacturing client faced unexplained shutdowns in their ammonia refrigeration plant. Their contractor blamed faulty compressors; the refrigeration tech blamed the switchboard. After weeks of downtime, the issue was still unresolved.

Our Solution:

• Installed a Fluke Power Quality Analyzer to monitor harmonics, spikes, and voltage dips.

• Discovered that starting currents from a nearby VSD-driven chiller were spiking THDI above 45%, tripping sensitive protection circuits.

• Installed a 300A Active Harmonic Filter (AHF) to smooth the distortion and rewired protection settings in compliance with AS/NZS 3000.

Outcome: No more nuisance trips, compressors back online, and the client saved tens of thousands in lost production.

2. “How do we ensure ammonia leaks automatically shut down our compressor room?”

The Challenge: A meat processing plant needed to enhance safety in their compressor room. In the event of an ammonia leak, staff safety was at risk, and there was no automatic shutdown in place.

Our Solution:

• Designed and installed a plant-wide ammonia detection system with multiple detectors.

• Engineered shunt-trip interlocks to instantly cut power to compressors if dangerous ammonia levels were detected.

• Added alarms and SMS/email notifications to alert management immediately.

Outcome: A fail-safe, life-saving system. The plant now operates with full confidence that staff are protected, and the risk of disaster is minimized.

3. “Our conveyors keep stopping out of sequence. How can we keep the line flowing?”

The Challenge: At a bakery, multiple conveyors moved dough and finished products between machines. When one conveyor stopped, others didn’t, causing pile-ups, blockages, and wasted product.

Our Solution:

• Installed safety and process interlock systems to ensure conveyors start and stop in sequence.

• Added load sensors and emergency stop controls for real-time safety response.

• Programmed a master control logic that prioritizes product flow while respecting safety interlocks.

Outcome: Smooth product flow, zero pile-ups, fewer stoppages, and happier operators. Production increased by 30% simply by syncing conveyors.

4. “Our new imported machine isn’t compliant — can you fix it?”

The Challenge: A client imported a $400,000 machine from overseas, only to find that it wasn’t wired to Australian standards, making it unusable and non-compliant.

Our Solution:

• Rewired the main control cabinet to meet AS/NZS 3000.

• Upgraded undersized circuit breakers and cabling.

• Installed proper RCD protection and relabelled the wiring to meet local conventions.

• Commissioned the machine with safety checks and certification.

Outcome: The client avoided a costly, non-compliant paperweight. The machine is now fully operational, safe, and compliant.

5. “How can we recycle water in our concrete plant and cut costs?”

The Challenge: A concrete supplier was spending thousands of dollars per month on fresh water, while wastewater from washdown bays and slurry pits was going to waste.

Our Solution:

• Designed a multi-tank water treatment facility with settling tanks, stirrers, chemical dosing pumps, and smart pumping systems.

• Built stainless steel enclosures with overhead cabling to handle harsh concrete environments.

• Automated the system with float switches, PLC controls, and molecule counters for water quality monitoring.

Outcome: The client now recycles 80% of their water, saving thousands annually and meeting environmental compliance.

6. “We’re adding new production lines but don’t have enough power — what now?”

The Challenge: A food manufacturer expanding production had maxed out their Main Switchboard (MSB) and transformer. Adding new equipment could risk overloading the system and causing blackouts.

Our Solution:

• Upgraded the site with a dedicated 1500 kVA transformer.

• Installed a new outdoor electrical kiosk with a custom-built MSB.

• Integrated a Total Power Factor Correction (TPFC) system to free up capacity and reduce network penalties.

Outcome: The site gained the capacity for future growth and reduced annual electricity costs by $40,000. Production could now expand without worrying about power outages.

7. “How do we keep equipment safe from corrosion in a salty, wet environment?”

The Challenge: United Barrel Services needed electrical systems for their skin salting barrels, operating in an environment filled with salt, brine, and constant washdowns — a perfect recipe for corrosion.

Our Solution:

• Built IP66 stainless steel enclosures with corrosion-proof glands and fittings.

• Installed cabling in stainless steel conduits with chemical-resistant sheathing.

• Designed PLC-controlled automation with interlocks and safety shutdowns.

Outcome: The salting barrels now run 24/7 with zero failures, saving UBS and their clients thousands in downtime and repairs. If you're facing electrical & automation problems in your industrial operations, you're not alone. Many businesses, like United Barrel Services, struggle with ensuring reliable and safe performance in harsh environments. In our detailed case study, we explore how EES Electrics helped United Barrel Services tackle corrosion and system failures in their skin salting barrels, leading to zero downtime and continuous operation.

Want to learn more about how we transformed their operations? Read our full case study on United Barrel Services and discover the tailored solutions we implemented to overcome these challenges and improve productivity in the global hide industry.

Why These FAQs Matter

These aren’t “Google-able” answers — they’re real-world, hard-earned solutions built on decades of industrial experience.

At EES Electrics, we:

• Solve problems most contractors walk away from.

• Engineer systems that are safe, compliant, and future-ready.

• Save clients' time, money, and frustration by getting it right the first time.
  

If you’ve got a problem that no one else can fix, chances are we already have the solution.