Across energy-intensive industries, maintaining reliable and safe power distribution is fundamental to operational continuity. At NewCo Ferronikeli Complex L.L.C, ABB and ELECTRA collaborated to replace decades-old infrastructure with a modern medium-voltage solution designed to improve reliability and operational resilience.
Facing the limits of legacy infrastructure
NewCo Ferronikeli operates a nickel production plant in Kosovo, where stable power is critical for continuous, energy-intensive processes. Even brief disruptions can halt production, introduce operational risk, and lead to significant financial losses.
The facility relied on medium-voltage equipment installed more than 40 years ago. As the system aged, performance became harder to maintain. Spare parts were increasingly difficult to source, maintenance demands grew, and meeting modern safety and technical standards became more challenging.
The need was clear: modernize the power distribution system to reduce risk, improve reliability, and support long-term operations, while minimizing disruption during implementation.
Delivering a future-ready medium-voltage solution
To address these challenges, the customer selected ABB’s UniGear ZS1 medium-voltage switchgear, delivered in collaboration with ELECTRA, an ABB Value Provider with strong local expertise. This combination ensured both proven technology and effective adaptation to site-specific requirements.
ELECTRA led the engineering design and system integration, tailoring the solution to the plant’s operational needs. The installation includes VD4 circuit breakers for reliable switching, Relion protection relays for protection and monitoring, and thermal sensors for continuous temperature tracking. High-quality current and voltage transformers support accurate measurement and coordinated protection. Together, these elements create a more stable, efficient, and safer power distribution system.
From legacy infrastructure to a modern ABB UniGear ZS1 installation supporting improved reliability and safety 
Switchgear room prior to modernization, featuring legacy medium-voltage equipment installed over 40 years ago. 
ELECTRA commissioning the new switchgear at the NewCo Ferronikeli Complex
These improvements are reflected in the customer’s experience:
"With this upgrade we see more stable operation. With improved power protection and monitoring, we are better equipped to prevent issues before they affect production. The transition to UniGear ZS1 switchgear has proven to be a successful and forward-looking investment, delivering substantial improvements across safety, reliability, and environmental performance" said Qamil Zogaj, Manager of the Project Management Department, at NewCo Ferronikeli Complex.
ELECTRA also highlights the value of the collaboration:
“With electrification and modernization needs continuing to grow, our long-term partnership with ABB ensures we can deliver high-quality solutions to meet evolving market demands. We benefit not only from proven products, but also from the strong technical expertise and support we can rely on as an ABB channel partner,” said Valon Gashi, Sales Director and Chief Production Officer, at ELECTRA.
Improving reliability and safety through modern protection and monitoring systems
This modernization has significantly strengthened the reliability of the plant’s power infrastructure. With improved protection, monitoring, and switching performance, the risk of unplanned downtime is reduced. Updated protection systems and well-proven components improve safety and simplify maintenance.
The new system also provides a foundation for future enhancements, including expanded monitoring and more advanced grid capabilities.
Through the combination of ABB’s technology and ELECTRA’s local execution, Ferronikeli has strengthened its ability to maintain continuous production in a demanding industrial environment, while being better prepared for future operational and regulatory requirements.
ABB’s delivery
- UniGear ZS1 medium-voltage switchgear
- VD4 circuit breakers
- Relion protection relays (REF615)
- Current and voltage transformers
Customer snapshot
NewCo Ferronikeli is a major mining and metallurgy company based in Kosovo, specializing in the production of ferronickel for global industrial markets. Established in 1984, the company operates a large-scale nickel production complex and is one of the country’s largest exporters.
Channel partner snapshot
ELECTRA LLC is an energy solutions company founded in 2008 in Kosovo, providing electrical design, infrastructure, and equipment for residential, commercial, and industrial projects. The company operates as an ABB Value Provider and is a licensed local manufacturer of ABB UniSec switchgear.
