Background
Rapiscan Systems is a global leader in security inspection technologies, providing advanced scanning solutions for airports, ports, customs agencies, and military operations around the world. Known for their reliability, innovation, and commitment to safety, Rapiscan’s systems are a cornerstone of international security infrastructure. If you’ve passed through an airport security checkpoint, you’ve likely encountered their scanning equipment in action. Their product range is extensive, covering everything from compact fixed security scanners to large-scale, mobile lorry scanners used for border control and high-security environments.
Challenge
Rapiscan approached us for advanced power protection for an international customer, presenting Kohler Uninterruptible Power (KUP) with a distinctive engineering and logistical challenge. These UPS systems needed to be custom-built, fully containerised, and then securely shipped overseas. The complexity of the project was compounded by the need to ensure the units would integrate flawlessly into Rapiscan’s sensitive scanning systems once on-site. This meant not only meeting rigorous technical specifications, all while maintaining strict quality control and compliance with safety standards.
Solution
Our expert team—including Nigel Harrington and Brooke Johnson—led this project from start to finish.
We designed, built, and delivered 55 PW 5000TP UPS units to meet the requirements for this project. In addition, we commissioned 66 PW8000 ST60 systems, each equipped with three 20kW modules and internal batteries. These were configured as 40kVA N+1 systems for added reliability. Each PW8000 unit came with a custom-built output transformer, stepping the voltage from 400V to 480V (to match the required standards). This design kept everything compact, saving valuable space inside their containers. These units were engineered specifically to integrate with Rapiscan’s scanning infrastructure, ensuring optimal performance and zero downtime during operation. We assembled and commissioned each UPS at their Stoke-On-Trent facility, then containerised to facilitate secure, damage-free transport to site for installation.
The seamless collaboration between our technical teams and Rapiscan’s engineers ensured that every unit functioned at peak efficiency from the moment it was powered on.
Results
Thanks to the success of this project, Rapiscan continues to choose us as a trusted partner for future initiatives.
Our ability to deliver tailored solutions, manage complex logistics, and integrate precisely with sophisticated technologies has solidified our reputation within the security and defence sectors. The performance of Nigel, Brooke, and the entire project team has not only met but exceeded expectations—cementing a long-term relationship built on trust, technical excellence, and collaborative execution.
