In today’s manufacturing plants, reliable power is non-negotiable. From automated production lines to precision robotics, even minor disruptions in voltage or current quality can ripple into costly downtime, equipment failures, and wasted energy.
Engineers are familiar with custom transformers as the backbone of power distribution — but often overlooked are the supporting components that make power truly stable: reactors and inductors.
At Control Transformer Inc, we believe that solving power quality challenges requires a system-level approach. Reactors and inductors, working alongside our custom transformer solutions, play a vital role in ensuring that your plant operates at peak performance.
Industrial facilities face some of the harshest power demands:
These issues aren’t minor inconveniences. Left unchecked, they can shorten motor life, trip protective devices, and even violate regulatory requirements such as IEEE 519, the global benchmark for harmonic distortion limits.
For manufacturers, compliance isn’t just about meeting a standard — it’s about avoiding penalties, reducing wear on equipment, and protecting productivity. Learn more in our article on Sustainable Transformers Meeting DOE Efficiency Standards.
Reactors and inductors act as the “shock absorbers” of an electrical system, protecting equipment from the stresses of harmonics and voltage fluctuations. Their value comes from being placed in the right location for the right purpose.
Installed between the power supply and a variable frequency drive (VFD), line reactors serve as the first line of defense. They reduce voltage spikes, limit harmonic distortion, and shield downstream equipment from transients that can shorten its lifespan.
Placed between the VFD and the motor, load reactors protect the motor itself. They reduce motor heating, minimize acoustic noise, and prevent insulation breakdown from voltage stress. The result is longer motor life and more reliable operation.
DC link reactors are located in the DC bus of a drive system. Their role is to smooth current flow, reduce ripple, and improve overall drive efficiency — a critical function in high-performance industrial environments where precision and reliability are paramount.
When combined with capacitors, inductors form passive filters designed to mitigate harmonics. These filters help facilities meet IEEE 519 harmonic limits, ensuring compliance while stabilizing power quality in even the most demanding manufacturing settings.
For industrial operators, the benefits go beyond “cleaner” power:
For example, in the fast-growing data center sector, improving power quality isn’t just a benefit — it’s essential to uptime.
Choosing the right reactor isn’t just a matter of adding impedance — it’s about striking a careful balance between performance and practicality. The design choices you make affect efficiency, compliance, and long-term reliability.
Reactors add impedance, which helps reduce harmonics and smooth current flow. However, too much impedance can lead to excessive voltage drop, lowering efficiency. The goal is to balance harmonic mitigation with stable voltage delivery to downstream equipment.
Where you place a reactor matters. Line reactors, installed at the supply side of a drive, primarily protect the drive itself from voltage spikes and harmonic distortion. Load reactors, positioned at the motor side, shield the motor from heating, noise, and insulation stress. The choice depends on whether your primary concern is drive longevity or motor protection.
The scale and configuration of your electrical system influence the level of inductance required. Large, complex plants often demand higher-inductance designs or multiple points of protection, while smaller systems may only need a single reactor for effective mitigation.
Every facility has a unique load profile, shaped by the types of drives, motors, and equipment in use. Reactors must be engineered to handle this profile while keeping harmonic content within limits such as IEEE 519. In some cases, a custom-engineered solution is the best way to ensure compliance and long-term reliability.
Control Transformer’s Expertise
At Control Transformer we don’t just build transformers — we engineer complete power quality solutions. Our team takes into account your facility’s load characteristics, harmonic challenges, and compliance requirements when designing systems.
Whether it’s integrating reactors into a new installation or advising on filtering strategies for an existing plant, CTI is committed to:
Curious about how we support renewables and electrification? Read more in Transforming Solar and Wind Energy with Custom Transformer Solutions.
Conclusion
Power quality challenges in industrial manufacturing are real, but they’re not insurmountable. With the right combination of transformers, reactors, and inductors, manufacturers can protect critical assets, meet regulatory standards, and maintain reliable production.
Control Transformer has the expertise to help you design and implement these solutions. Let us put your power quality under control — so your operations can run stronger, longer, and smarter.
👉 Ready to improve your plant’s power quality? Contact CTI today to discuss a tailored solution for your facility.