Bay Footwear Limited

Bay Footwear Limited (Unit-2) — 7.5 MVA Manufacturing Power Substation | POWERtrac

Keeping the Production Line Moving — One Precisely Engineered Megavolt-Ampere at a Time.

Behind every pair of footwear that leaves Bay Footwear Limited's Unit-2 facility in Gazipur is a factory running on precision — precision stitching, precision cutting, and now, precision power. POWERtrac designed and commissioned a complete 7.5 MVA industrial substation solution that ensures this high-output manufacturing plant never misses a beat due to electrical failure, voltage instability, or energy inefficiency.

The Manufacturing Power Challenge

Footwear manufacturing is a power-intensive, multi-process operation. Hydraulic presses, conveyor systems, injection moulding machines, compressors, and high-speed finishing equipment all run concurrently — each drawing significant electrical load, each sensitive to voltage irregularities. A substation that can't keep up with peak demand or can't recover quickly from a fault doesn't just cause delays. It causes production losses, equipment damage, and costly rework. For a facility the scale of Bay Footwear Unit-2, only a purpose-engineered industrial power solution is acceptable.

What POWERtrac Delivered

7.5 MVA Power Transformer with OLTC: The project's central component — a large-capacity On-Load Tap Changer transformer that maintains stable output voltage in real time as manufacturing loads fluctuate across production shifts. The OLTC mechanism adjusts tap positions under live load, eliminating voltage dips that could disrupt sensitive machinery without any interruption to operations.

Outdoor 33 kV HT Switchgear: Heavy-duty outdoor high-tension switchgear at the 33 kV primary entry point provides reliable fault interruption and switching capability — forming the first and most critical line of electrical protection for the entire facility.

Cast Resin Distribution Transformers: In place of conventional oil-filled units, cast resin (dry-type) distribution transformers were selected for their superior fire safety, lower maintenance requirements, and suitability for demanding industrial environments — an ideal choice for a busy manufacturing floor with minimal tolerance for hazard.

High-Capacity LT Switchgear: Robust low-tension switchgear panels manage the final distribution of power to all machinery, utilities, and support systems across the factory — delivering controlled, protected electricity exactly where it's needed, at the capacity the factory demands.

Automatic PFI Plant: An automatic Power Factor Improvement plant continuously monitors the facility's reactive power consumption and corrects it in real time — reducing energy wastage, cutting monthly electricity costs, protecting motors and transformers from unnecessary stress, and keeping Bay Footwear Unit-2 compliant with utility power factor requirements.

Full System Testing & Commissioning: Every element of the installation was rigorously tested, integrated, and commissioned as a single cohesive system before handover — ensuring the plant was ready for full production load from the very first day.

The Result

A reliable, efficient, and safety-first 7.5 MVA industrial power substation purpose-built for the non-stop demands of footwear manufacturing in Gazipur's competitive industrial zone. The system delivers stable voltage, reduced power losses, improved energy efficiency, and built-in electrical safety — giving Bay Footwear Limited the power confidence to focus entirely on what they do best: manufacturing world-class footwear at scale.