Case Study: Husqvarna’s robotic lawnmower manufacturing plant upgrades outdated electrical system to elevate reliability

Pursuing disruptive technologies with the shiny goal of transformational change is not a high priority for organizations with immediate needs and lean budgets. Rather, they continue to advance their operations and maintenance effectiveness with more focused solutions. 

The Husqvarna Manufacturing CZ facility in Vrbno pod Pradědem, Czech Republic, is one of those. The robotic lawnmower manufacturing plant chose swift modernization over full capital replacement when aging infrastructure posed a risk to operational reliability.

An installed base of switchgear dating back to the 1960s was still operational, which is a testament to the maintenance and reliability team’s strength as well as the quality standards of the original equipment manufacturer (OEM). But it was clear that upgrading the electrical system would significantly enhance power reliability and resilience and reduce costly downtime, making the organization safer and more successful at multiple levels. 

To arrive at this approach, Husqvarna leveraged ABB Navigate advisory services, delivered by ABB’s Electrification Service team, for a comprehensive technical assessment and targeted modernization recommendation. Based on that recommendation, the plant’s aging medium-voltage switchgear was upgraded with state-of-the-art switches.

With its electrical infrastructure modernization, Husqvarna’s flagship robotic lawnmower plant is saving thousands of euros for each hour of avoided unplanned downtime. The sustainable solution also reduced the need for large capital expenditures and is helping to safeguard operations, extend equipment life, and support long-term performance.

Outdated electrical installed based posed growing risks to safety and reliability

The Vrbno pod Pradědem site produces plastic parts using injection molding technology and assembles robotic lawnmower kits, among other products. It operates 24 hours per day, seven days a week, making operational reliability and a dependable power backbone essential. Yet with an electrical installed base dating back nearly six decades, issues with obsolete equipment, declining spare parts availability, and limited servicing options put availability and uptime at risk. 

“Unplanned downtime can cost our facility thousands of euros per hour, which is why a reliable and predictable power supply is crucial,” says Pavel Jiroušek of Husqvarna Manufacturing, Czech Republic. “We needed a sustainable solution that focused on modernizing rather than replacing our existing installed base of switchgear. A solution that offered swift implementation and minimum disturbance to our operations.”

Technical expertise and tailored solutions enabled efficient upgrade of legacy electrical systems

Husqvarna worked with ABB, a trusted partner, to determine and implement an optimal solution. ABB Navigate advisory services, delivered by ABB’s Electrification Service team, included a comprehensive technical assessment and development of a recommended modernization plan. 

The mutually accepted solution was to upgrade the plant’s aging medium-voltage switchgear by replacing outdated load break switches with new NAL/NALF air-insulated switches, which rapidly extinguish electrical arcs and support high switching capacity. Their modular build shortens installation time, and after commissioning they can run for 15 years before requiring service.

“These units are rated to M1 mechanical and up to E3 electrical endurance classes, with a visible open insulation gap and a wide -40/+55 °C operating envelope,” says Marco Tellarini, senior vice president – EMEA region, ABB Electrification Service.

Decidedly targeted upgrade fosters Husqvarna’s journey toward greater reliability and sustainability

Modernizing the aging electrical infrastructure by transitioning from outdated medium-voltage switchgear to new air-insulated switchgear proved to be an efficient and cost-effective solution for Husqvarna's robotic lawnmower manufacturing facility. 

Significant savings arise from protecting against costly equipment failure, plant disruption, and unplanned outages, gaining more than a dozen years of maintenance-free operation and extending equipment life. The predictable power supply enhances operational safety, resilience, and long-term reliability. Additionally, modernization supports Husqvarna’s circular approach by prioritizing the sustainable reuse of existing infrastructure over full replacement.

"Too many industrial operators still view electrical modernization as a deferrable maintenance expense rather than the competitive lever it has become,” observes Tellarini. “At Husqvarna's Vrbno pod Pradědem plant, swapping obsolete load break switches for modular NAL/NALF air-insulated units delivers 15 years of service-free operation.”

The comprehensive technical assessment behind the project also secured a foundation for future digital investment across the installed base. “When downtime costs thousands of euros per hour, that blend of near-term reliability and long-term digital headroom is what makes targeted upgrades pay back so quickly," Tellarini explains.

ABB’s 140 years of expertise in electrical systems facilitates safer, smarter, and more sustainable futures for its customers

Though not specifically quantified by the Husqvarna plant, ABB’s internal analysis of customer successes shows that projects relating to ABB Navigate advisory services typically result in a 25% reduction in downtime by mitigating risks of failure, 50% reduction in safety incidents, and 30% reduction in energy consumption by integrating sustainable technologies and energy-efficient practices.