The company is one of the largest manufacturers of polymer packaging in Ukraine, operating modern automated production lines and processing significant volumes of polymer raw materials.  The production operates in a continuous cycle format, where stable energy supply is a critical factor in ensuring product quality and efficiency of technological processes. The number of employees exceeds 500.

Note: For security reasons and due to ongoing attacks on Ukraine’s energy and industrial infrastructure, the name of the client company is not disclosed.

Task

The company operates an energy-intensive and continuous production cycle, therefore reliable energy supply is a mandatory condition for stable operations.

An additional challenge was the increase in electricity and heat tariffs, which directly affected production costs and the company’s competitiveness.

Key project objectives:
• ensuring uninterrupted energy supply for production
• reducing dependence on external power grids
• improving energy efficiency
• reducing energy costs

A specific feature of the project was the need to install energy equipment inside the existing building, taking into account safety, ventilation, and noise requirements.

Solution

The optimal solution was the implementation of an on-site cogeneration power plant, enabling simultaneous production of electricity and heat with high efficiency. Based on a techno-commercial analysis, a solution using the Jenbacher JMS J620 gas engine operating on natural gas was selected. KTS specialists proposed a solution based on Jenbacher JMS J620 units. Under the contract, KTS Engineering supplies the equipment, and the scope also includes commissioning works and subsequent service maintenance.

In 2025, a project was implemented involving the installation of a Jenbacher JMS J620 GS-N.L. cogeneration unit operating on natural gas. The unit provides combined generation of electrical and thermal energy, fully covering the company’s demand during peak loads.  The system can operate both in parallel with the external grid and in autonomous (“island”) mode, ensuring production continuity even in case of emergency power outages.

Results

The implementation of the cogeneration unit achieved the following results:

• ensured stable and uninterrupted energy supply for production
• achieved a high level of energy independence
• reduced dependence on external energy factors
• optimized the company’s energy consumption structure
• reduced electricity and heat costs
• improved overall energy efficiency of production
• minimized risks of emergency shutdowns and downtime
• ensured stable equipment operation under variable loads

The project demonstrates that on-site generation is not only a cost reduction tool but also a critical element for ensuring continuous production.

Solution features

1. Island Mode Operation. The Jenbacher J620 unit can operate автономously or synchronously with the grid without power export, ensuring guaranteed supply to critical loads.

2. High Efficiency. Achieved through combined generation of electricity and heat.

3. Economic Effect. The cost of generated energy is lower than market tariffs, ensuring project payback.

4. Operational Flexibility. The ability to operate in different modes allows the company to optimize loads depending on production needs.

5. Digital Monitoring. The installed myPlant system provides remote monitoring, performance analysis, and real-time alerts for abnormal conditions.

Solutions implemented by KTS Engineering enable industrial enterprises to:

• control energy consumption
• improve stability of production processes
• reduce downtime risks
• enhance competitiveness under unstable energy supply conditions