Article: solar hybrid systems

Hybrid Solar Systems with Diesel Generators for Remote Areas

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Hand inspecting a solar panel in a solar hybrid system installation.

What is a Hybrid Solar System and How Does It Work?

Hybrid solar systems are energy solutions that combines solar photovoltaic power with another generation source, usually a diesel generator or a battery storage system. Its purpose is to ensure a continuous, stable and efficient electricity supply, even in areas without access to the electric grid or where the connection is unreliable.
In a solar hybrid system, photovoltaic panels capture solar radiation and convert it into electrical energy. This electricity is used to power local consumption or charge the solar batteries, which store the excess energy for later use.

Solar batteries are a key component in hybrid energy systems.

When solar radiation is insufficient or the batteries are depleted, the diesel generator starts automatically to cover the energy demand. The hybrid inverter intelligently manages the available energy sources, prioritising solar power and optimising fuel consumption.

Advantages of Combining Solar Energy with Diesel Generators

Hybrid solar energy systems offer a sustainable and cost-effective alternative to conventional diesel-only systems. Their main advantages include:

  • Fuel savings: by using solar energy, the operating hours of the diesel generator are significantly reduced, lowering operational costs.
  • Reduced emissions: less diesel consumption means lower CO₂ emissions and environmental impact.
  • Greater autonomy: the combination of both sources guarantees 24/7 power supply, even under adverse weather conditions.
  • Lower maintenance: fewer operating hours extend the lifespan of the generator.
  • Total reliability: the hybrid solar-diesel system ensures a stable power supply in locations where the grid is unavailable or unstable.

For these reasons, hybrid solar systems are an ideal solution for remote areas, critical facilities, rural environments or industrial projects far from the grid.
Technician measuring the performance of a solar panel with a multimeter.

Key Components of a Solar-Diesel Hybrid System

A hybrid solar photovoltaic system is made up of several essential components that work together efficiently:

  • Solar photovoltaic panels, which capture sunlight and generate electricity.
  • Hybrid inverter, which manages the conversion from DC to AC and controls the energy flow between sources.
  • Solar batteries, which store energy for use during low or no sunlight hours.
  • Diesel generator, which automatically starts when solar and stored energy are insufficient.
  • Control and monitoring system, coordinating operations for maximum efficiency.
  • Electrical panels and protections, ensuring safety throughout the installation.

Types of Hybrid Solar Systems by Configuration

Different types of hybrid solar systems exist depending on their connection and operation mode:

  • Grid-connected systems: combine solar, diesel, and grid energy. When grid power is available, solar energy is prioritised; the generator acts only as backup.
  • Off-grid or stand-alone systems: operate without a grid connection. These are ideal for remote sites and must be properly sized for solar generation, diesel backup and battery capacity.
  • Modular hybrid systems: allow adding panels, batteries or generators as energy needs grow. Their scalability makes them especially suitable for industrial projects or rural electrification.

Technicians inspecting a solar panel in a technical work environment.

The Role of Batteries in Energy Storage

Solar batteries are a key component in hybrid energy systems, storing energy generated by photovoltaic panels for later use.
They make it possible to have electricity available at night or during low-sunlight periods, minimising the need to start the diesel generator.

Ongoing innovation will make solar hybrid systems increasingly efficient, reducing diesel consumption.

Choosing the right battery type and capacity — lithium, AGM or gel — directly impacts the system’s efficiency, performance and lifespan.

How to Optimise Consumption and Reduce Diesel Use

The main goal of a solar-diesel hybrid system is to reduce fuel consumption without compromising power continuity. Key strategies include:

  • Installing smart controllers that prioritise solar energy use.
  • Adjusting generator operation times to match demand.
  • Incorporating high-efficiency batteries to increase autonomy.
  • Carrying out preventive maintenance to maximise generator performance.
  • Designing a photovoltaic installation properly sized for peak demand.

Applications and Use Cases in Remote Areas

Hybrid solar systems with diesel generators are widely used in applications where grid access is limited or non-existent:

  • Critical infrastructure: telecommunications, weather stations and healthcare facilities.
  • Remote industrial operations: mining, oil and gas, civil works or water treatment plants.

Aerial view of a rural area with wide fields and scattered buildings.

  • Rural areas and isolated communities, enabling electrification where the grid cannot reach.
  • Emergency or military projects, requiring autonomous, robust and fast-deployable energy.

Thanks to their flexibility, hybrid solar systems provide continuous and sustainable power even in the most demanding environments.

Trends and the Future of Hybrid Solar Systems

The future of hybrid solar photovoltaic systems is driven by digitalisation, improvements in battery capacity, and integration with smart management technologies.
Ongoing innovation will make solar hybrid systems increasingly efficient, reducing diesel consumption, advancing decarbonisation, and increasing the energy independence of remote areas.

In a solar hybrid system, photovoltaic panels capture solar radiation and convert it into electrical energy.

In this evolution, diesel generators will continue to play a crucial role as reliable backup units within hybrid energy solutions, ensuring continuity when renewable sources are insufficient.
The trend is clear: combining solar energy with efficient, flexible generation technologies will be key to guaranteeing a stable, sustainable, and adaptable power supply for the energy challenges of the future.

Article: Omnibus Regulation

Simplifying to Move Forward: How We Apply the Spirit of the Omnibus Regulation

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Bosque iluminado por el sol como metáfora del avance hacia una sostenibilidad más simple impulsada por el Reglamento Ómnibus.
Sustainability is entering a new phase. After years of directives, reports, and standards, Europe has realised that reporting alone is not enough — what matters is not how much is reported, but how much is transformed. With the approval of the Omnibus Regulation, the European Commission is taking a decisive step in that direction, simplifying the way companies report their environmental, social, and governance performance so that sustainability regains the meaning it should never have lost: action.

Properly managed sustainability not only reduces costs or emissions — it also opens doors.

This regulation was not created to lower ambition, but to restore coherence. In recent years, the CSRD Directive and the European Sustainability Reporting Standards (ESRS) have raised the bar for corporate reporting, but in doing so, they also imposed a disproportionate burden on many SMEs. It’s not just about gathering information: the CSRD required companies to measure dozens of environmental, social, and governance indicators with the same level of detail as large corporations. For an industrial SME, that means allocating human and financial resources it may not have, creating complex management systems, investing in digital tracking tools, and training staff in methodologies that until recently were exclusive to multinational ESG departments. In practice, sustainability was starting to look more like an exercise in bureaucracy than a process of improvement, diverting attention from the real goal: reducing impacts and creating value.
Team analysing data to apply the criteria of the Omnibus Regulation.
The Omnibus Regulation, approved in 2025, aims to correct that course. Its goal is to simplify administrative burdens and focus on material indicators — those that truly reflect an organisation’s impact on its surroundings. It’s essentially the same approach that guides our evolution: data that inspire decisions, measurements that drive change, sustainability that translates into action.

Measuring What Matters — and Acting on What Can Be Measured

At Genesal Energy, we’ve always understood sustainability as a tool for innovation and improvement, not a reporting obligation. That’s why, even before the Omnibus Regulation came into force, we were already working under the principles it now promotes: prioritising what’s relevant, reducing complexity, and focusing management on tangible results.
The new European framework particularly strengthens three key areas — those that concentrate most of the changes introduced by the Omnibus Regulation:

  • E1: Climate change. Updated requirements for measuring greenhouse gas emissions, improving energy efficiency, and advancing towards a genuine transition to clean energy.
  • E5: Resources and circularity. Simplified indicators with greater emphasis on responsible use of materials, waste reduction, and the adoption of circular economy principles.
  • S1: People and the value chain. Strengthened social aspects: training, occupational health and safety, and ethical management across the entire supply chain.

E1. Climate Change: More Efficient Energy, Lower Impact

Our commitment to climate action is reflected in the way we manage energy. At our facilities in Bergondo (A Coruña), we have developed a model that integrates renewable sources, smart storage, and consumption optimisation.
Genesal Energy facilities
The photovoltaic façades and roofs of our B27 and B28 plants generate part of the electricity we consume. Thanks to OGGY, our energy management and storage system, we can monitor production, consumption, and energy flow in real time. Its algorithm automatically decides whether to self-consume, store, or feed energy back into the grid — optimising every kilowatt used.

The results are tangible:

  • We have reduced our annual energy consumption by 27%.
  • We have improved the energy efficiency rating of our facilities from Category E to B.
  • We avoid more than 23 tonnes of CO₂ emissions per year.

These figures are more than indicators — they are proof that sustainability is also a matter of engineering. Our industrial complex now operates as a small microgrid: an energy ecosystem capable of producing, storing, and managing its own electricity efficiently and autonomously.

E5. Resources and Circularity: Designing for the Entire Lifecycle

In this new European context, responsible resource management has become more relevant than ever — and at Genesal Energy, we have long been working in that direction. Efficient use of materials, waste reduction, and the incorporation of circular economy criteria are at the core of our eco-design policy.

That’s why we implemented an eco-design management system certified under ISO 14006, which enables us to assess the impact of each component, material, or manufacturing process — and redesign wherever there’s room for improvement.

Simplify administrative burdens and focus on material indicators — those that truly reflect an organisation’s impact on its surroundings.

This work has led to concrete progress:

  • Replacement of conventional materials with recycled or recyclable ones — for example, replacing metal parts with 3D-printed recycled polymers, reducing emissions linked to transport and processing.
  • Incorporation of local suppliers (km 0) to cut the logistics footprint.
  • Elimination of welding or painting processes in certain components, reducing emissions and waste.

Thanks to these actions, some components have reduced their carbon footprint by more than 80% compared to the original materials.
But eco-design goes beyond the technical aspect — it also transforms the way we communicate. Our eco-designed products include environmental data and comparisons that allow clients to understand the savings in emissions and materials compared to previous models. This transparency is part of our commitment: providing clear, useful, and verifiable data that reflect the positive impact of every improvement we make.
Wildlife in a natural environment and an industrial process with machinery.

S1. People and Knowledge: Learning to Transform

Sustainability is not limited to technology or processes; it also has a human dimension that is essential for progress. At Genesal Energy, we understand that knowledge, education, and social collaboration are fundamental pillars for building a fair and lasting energy transition — and we channel that commitment through the Genesal Energy Foundation.
Through the Foundation, we promote educational, social, and environmental projects that reflect our understanding of sustainability as a shared effort between business and society. We carry out training and awareness activities on energy and environmental issues, support cultural and social initiatives in our local community, and collaborate with organisations working towards more balanced and sustainable development.

Efficient use of materials, waste reduction, and the incorporation of circular economy criteria are at the core of our eco-design policy.

Our goal is to create a positive impact that goes beyond industrial activity — contributing to people’s well-being and to the progress of the environment in which we operate. We believe sustainability begins in the factory, but only becomes meaningful when it’s shared — when knowledge, responsibility, and social action move forward together.

From Measurement to Action

Measurement only makes sense if it leads to action — and at Genesal Energy, we’ve been living by that principle for years. Our environmental policy and management systems — certified under ISO 14001, ISO 14006, ISO 45001, ISO 9001, and UNE 166002 — enable us to turn indicators into technical and business decisions.
Coral reef with colourful fish swimming in clear waters.
We measure our emissions, consumption, and waste — but what matters most is what we do with that information: we select sustainable suppliers, redesign parts, optimise packaging, improve testing efficiency, and reduce impacts at every production stage. In our experience, industrial sustainability is managed with the same precision as any engineering process. It’s not a separate part of the business — it’s part of the way we design, manufacture, and operate.

The new European framework reinforces this vision. Properly managed sustainability not only reduces costs or emissions — it also opens doors. It allows us to access green financing, participate in European projects, and be chosen by clients who value vision and environmental commitment. Sustainability is no longer an obligation; it’s a credential — and a guarantee: the mark of a company that innovates, adapts, and embraces its role in the energy transition with coherence and responsibility.

Dense forest covered in mist.
That’s why we continue to work by a simple principle: less bureaucracy, more innovation; fewer papers, more clean energy; less noise, more consistency.
Europe’s energy transition will be built on data — but above all, on examples. And ours is that of an industrial SME that has decided to integrate sustainability into its DNA — not as a distant goal, but as a way of moving forward every day.

Energy security in car parks: a new project in a public car park in France

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Car parks, particularly when underground or large-scale, require a continuous power supply to ensure car & people’s protection (energy security in car parks). In the event of an outage, ventilation systems would stop working, and the risk of poisoning could rise within minutes.

Similarly, without emergency lighting or active signage, evacuation during a fire could be compromised, creating dangerous and panic situations.

Our latest project in this area has been the design and manufacture of a bespoke tailor-made genset for a public car park in France to guarantee power supply in the event of a mains failure ensuring compliance with the strict safety regulations applicable to public spaces of this kind.

A vital need in a busy environment

Our engineering team developed a 250/275 kVA genset housed in a 3400mm soundproofed canopy, equipped with a Baudouin engine and a high-performance Leroy Somer alternator. This design ensures reliability, durability and ease of maintenance.

Guarantee power supply in the event of a mains failure ensuring compliance with the strict safety regulations applicable to public spaces.

The generator is fitted with a built-in 500-litre tank, providing up to 8 hours of autonomy, thereby ensuring critical systems remain operational for an entire day in the event of an incident. To further enhance safety, we integrated specific features such as externally operable fuel shut-off valves, redundant control & battery systems, protections against moving and hot parts, and emergency stop push-buttons.

Reliability, safety and continuity

Beyond the robustness of the equipment itself, reliability in this project is reflected in compliance with strict French safety regulations, specifically NF-E-37-312, applicable to this type of installation. This means that the genset not only provides backup power but also ensures the installation meets the highest standards of protection and risk prevention.

Features

  • Design type: Monoblock in 3400mm soundproofed canopy.
  • Fuel tank: 500 litres integrated into the base frame.
  • Control panel: ComAp InteliLite AMF25 IL4.
  • Redundant battery system.
  • Emergency start controller: ComAp InteliNano.
  • Safety fuel shut-off valve.
  • Compliance with NF-E-37-312 safety regulations.

Genesal Energy designs tailor-made generator sets for large retail outlets.

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Genesal Energy has designed a generator set to guarantee energy in a shopping centre in Germany and replace its previous generator.

The genset had to be integrated without the need to modify the existing installations and to have a high autonomy and direct connection to an external fuel tank.

With these indications, our engineering team designed a solution with the necessary features to replace the previous equipment without the need for major modifications existing infrastructure. The control unit was located in a special position that allows access without the need to open the side doors, enhancing space and operability at both an operational and aesthetic level, as it also complied with the specific colour and marking requested.

Our proposal included a control unit in a special position which can be accessed without having to open the side doors of the set.

Bearing in mind that shopping centres are spaces where activity does not stop, the electricity supply must be guaranteed at all times to ensure its proper functioning, as a failure in the grid can lead to operational interruptions, affecting customers, generating economic losses and compromising the safety of the premises.

To prevent this kind of situation, this set has an automatic start-up system, ensuring its immediate activation in the event of a failure in the main network. In order to achieve maximum autonomy, the engineering team designed an external fuel tank by means of wall-bushings, allowing a continuous supply without the need for frequent refuelling.

Thanks to this Genesal Energy design, the shopping centre has a reliable solution adapted to its needs, ensuring that, in the event of any grid failure, activity continues without interruption.

Our Engineering Solution

Based on the client’s specific need to replace an old unit with this new one, we designed a unit as similar as possible to the already existing. Our proposal included a control unit in a special position which can be accessed without having to open the side doors of the set. It was installed in the same precise location without having to make any modifications.

Features

  • AMF Mains failure start.
  • Deif AGC 150 control panel.
  • No fuel tank integrated in the base, only liquid collection tray with sensor for leak detection.
  • Wall bushings for fuel lines (suction and return) from external tank.
  • Protective mesh against animals (at air inlet and outlet).
  • Special customer marking.
  • Unit painted in the customer’s required colour – RAL 5003.
  • Oil extraction hand pump.
  • Heating water recirculation pump.
  • Fuel pre-filters with water decanter.
  • Special batteries.
  • Completely covered power supply preventing any access to live parts.
Article: How to calculate the kVA of a generator set

How to Calculate the kVA Required for a Generator

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Technician inspecting an electrical panel while checking performance data on a tablet.
Choosing the right generator involves much more than just looking at the brand or the price. One of the most important aspects is knowing how to calculate the kVA of a generator to ensure it will meet all your energy needs without oversizing the unit or compromising its performance.

At Genesal Energy, we specialise in the correct dimensioning of generator sets and in designing tailor-made solutions for each client.

This value represents the generator’s power, expressed in kilovolt-amperes (kVA). In this article, we explain step by step how to carry out the calculation, which factors to consider, and how to apply a safety margin.

Key Factors to Determine a Generator’s Power

Before going into formulas, it is essential to understand the elements that directly influence the kVA calculation for a generator. The main ones include:

  • Type of electrical consumption: it is not the same to power office equipment as industrial machinery.
  • Intended use: whether the generator will serve as the main power source or as backup.
  • Number and type of electrical devices connected: each appliance has different power requirements.
  • Starting conditions: some equipment requires start-up peaks much higher than their constant consumption.
  • Load sequence: in certain facilities, it may be advisable to prioritise loads by connecting them in stages.

By analysing these factors, you can calculate the power of a generator with greater accuracy.

Difference Between kVA and kW in a Generator

A common mistake when calculating the power of a generator is confusing kVA (kilovolt-amperes) with kW (kilowatts).

  • kVA expresses the apparent power of the generator.
  • kW indicates the actual power consumed by the connected electrical devices.

The relationship between these values is defined by the power factor (cos φ). In most installations, it is common to use a factor of 0.8, meaning that a 100 kVA generator can deliver around 80 kW of useful power.
It is also important to note that apparent powers cannot simply be added together, as each load may operate with a different power factor. Instead, the real powers in kW must be added first and then converted into kVA.
This distinction is typical of alternating current circuits. In direct current, the power factor is 1, and the real and apparent powers coincide.
Professional analysing electrical consumption on screen and measurement tools (kW and kVA).

How to Calculate Power Based on Electrical Consumption

To calculate generator kVA, the starting point is the total power of all the electrical devices to be connected. This information can be found on each device’s nameplate or in its manual.
The basic procedure is:

  • 1. Add up the power ratings in kW of all the equipment.
  • 2. Apply usage or simultaneity factors, if necessary, to reflect a realistic scenario.
  • 3. Convert to kVA using the formula: kVA = kW / power factor
  • 4. Round up to the next value to ensure the generator does not operate at 100% of its capacity.

In this way, you can calculate the required generator kVA reliably and safely.

The Importance of Power Factor in kVA Calculation

The power factor is essential to convert kW into kVA. As mentioned, the usual reference value is 0.8, but it may vary depending on the type of load:

  • With electric motors, the power factor may be lower.
  • With modern electronic devices, it may approach 1.

Failing to account for this can lead to errors in sizing and selecting an undersized generator. It is always advisable to confirm this value with a specialist before choosing the equipment.
Technician checking load parameters on a tablet to calculate the kVA required for a generator set.

Considerations on Start-Up Peaks and Constant Power

Many electrical devices, particularly motors, pumps, and HVAC systems, generate start-up peaks when switched on. These peaks can be two to three times higher than their rated power.

For example, a motor with a rated power of 35 kW may require more than 70 kVA at start-up.
There are two common ways to compensate for these peaks:

  • Oversizing the generator’s alternator.
  • Incorporating frequency converters or other auxiliary equipment to soften the initial demand.

How to Apply a Safety Margin When Choosing a Generator

Once the required kVA has been calculated, it is advisable to apply a safety margin. This prevents the generator from always working at its limit, extends its service life, and reduces fuel consumption.

One of the most important aspects is knowing how to calculate the kVA of a generator to ensure it will meet all your energy needs.

In general, a margin of 20–25% above the initial calculation is recommended. For example, if the result is 100 kVA, the most appropriate choice would be a 120–125 kVA generator.

Practical Example of kVA Calculation for Different Loads

Let’s suppose a facility requires a generator with the following loads:

  • Lighting and office equipment: 15 kW
  • Air conditioning: 20 kW
  • Electric motors: 30 kW
  • 1. Sum of real power: P=15+20+30=65 kW
  • 2. Apply the power factor (0.8): S=P/cosϕ=65/0,8=81,25 kVA
  • 3. Consider start-up peaks: this value may rise to around 100 kVA.
  • 4. Apply a safety margin (+25%): 100×1,25=125 kVA

In this case, the correct option would be a 125 kVA generator, ensuring it can cover both constant power and start-up peaks without compromising performance.
Technician inspecting industrial machinery and recording consumption.

Conclusion

Understanding how to calculate the kVA of a generator is essential to choose the right equipment and avoid supply issues. Remember:

  • Differentiate between kW and kVA.
  • Always consider the power factor.
  • Account for start-up peaks, not just constant power.
  • Always apply a safety margin.

Correct sizing guarantees that the generator’s power matches the real needs of the installation, optimising performance and ensuring reliability.

Understanding how to calculate the kVA of a generator is essential to choose the right equipment and avoid supply issues.

At Genesal Energy, we specialise in the correct dimensioning of generator sets and in designing tailor-made solutions for each client. If you need advice on how to calculate kVA for purchasing a generator, our technical team can help you find the best option.

Tailored Power for a Shopping Mall in Germany

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Genesal Energy understands that every client is unique and when it comes to securing power supply in critical facilities, there’s no such thing as a one-size-fits-all solution.

A key part of our work lies in listening carefully, understanding each project in depth, and designing fully customised gensets capable of meeting even the most specific requirements.

This was the case in one of our most recent projects: the design and manufacture of a generator set for a shopping centre in Germany. The client presented us with a highly specific set of technical requirements. It was an ambitious challenge, as they needed a reliable emergency power solution with clearly defined criteria regarding autonomy, aesthetics, corporate branding and weight restrictions.

The client required a high-autonomy genset, connected to a 3,000-litre belly tank fully integrated into the base frame, a design that enables the installation to operate for extended periods. Additionally, there was a strict total weight limit of 8.5 tonnes, including the fuel tank, which meant we had to completely redesign the canopy and manufacture it in aluminium to reduce weight without compromising strength or performance.

A full redesign of the canopy, which was manufactured in aluminum to reduce weight.

Accordingly, the genset was customised both functionally and aesthetically. It was painted in the client requested RAL and featured special corporate branding. From a technical perspective, the set includes an oversized alternator to ensure optimal performance under demanding conditions, a ComAp InteliGen4 200 control panel, animal ingress protection mesh, and a fully covered power section to eliminate access to live parts, among other specifications.

This project is a clear example of what we do at Genesal Energy: delivering power solutions that combine innovation, flexibility, and deep technical expertise. Whether the challenge lies in the design, available space, local regulations or visual integration, our team is always ready to respond with the best solution.

The Engineering Solution

A full redesign of the canopy, which was manufactured in aluminum to reduce weight. This ensured the final equipment – including the full 3,000-litre tank – remained under the specified weight limit.

Main Features

  • ComAp InteliGen4 200 control panel.
  • 3,000-litre belly tank integrated into base frame.
  • Spill containment tray with leak detection sensor.
  • Animal protection mesh at air inlet and outlet.
  • Special client-specific branding.
  • Painted in RAL 7035 (client’s specified colour).
  • Manual oil extraction pump.
  • Coolant recirculation heating pump.
  • Fully covered power section to prevent contact with live components.
  • Oversized alternator.

Backup power in critical healthcare environments: we designed a tailored emergency solution for a proton therapy centre

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Genesal Energy designed and manufactured a soundproofed generator set specifically adapted for a proton therapy centre located in Santiago de Compostela (Spain).

This emergency power solution delivers 550 kVA to ensure the uninterrupted operation of high-precision medical equipment in the event of a grid failure.

These types of centres, dedicated to oncology treatments using protons, require a continuous power supply, as any interruption can not only compromise the effectiveness of the treatment but also put patient safety at risk. In addition, international regulations on advanced radiotherapy impose the mandatory requirement of having backup energy systems in place.

Generator sets for critical healthcare environments: safety, precision, and autonomy

Genesal Energy’s engineering department developed a GEN550YI generator set housed in a 4,500mm soundproofed enclosure, providing quiet operation and reliable performance. The generator starts up automatically in the event of a power outage, supplying the necessary energy to keep facilities and medical equipment running.

A dedicated exhaust system was also designed to minimise noise emissions, in compliance with current noise regulations.

Alongside reliability, the project required a solution with high operational autonomy. Two fuel tanks were included: an 800-litre base frame tank and an external double-walled fuel tank with a 2,000-litre capacity. Both are connected through an automatic transfer system equipped with level sensors, a transfer pump, a cut-off solenoid valve, and a fuel filter, thus ensuring a continuous and safe supply.

A robust and silent design

The solution also incorporates a redundant start-up system with batteries in parallel to ensure the generator remains operational at all times. A dedicated exhaust system was also designed to minimise noise emissions, in compliance with current noise regulations.

The unit was manufactured using state-of-the-art technology, integrating a monoblock engine–alternator system with flexible coupling, which enhances overall reliability and reduces vibrations. Thanks to this bespoke design, the proton therapy centre in Santiago now benefits from a reliable, quiet, and long-lasting backup system that protects sensitive and costly equipment, guarantees the continuity of advanced medical treatments, and complies with the highest technical and regulatory standards in the healthcare sector.

Technical features

  • Construction type: Monoblock engine–alternator in 4,500mm soundproofed enclosure.
  • Flexible coupling between engine and alternator.
  • 800-litre integrated base frame tank + 2,000-litre external double-walled tank.
  • Automatic fuel transfer system with pumps and level sensors.
  • Oversized silencer model (-30 dB).
  • Redundant battery & start system.
  • Bespoke cooling air intake and hot air exhaust.
Article: Reducing emissions in diesel generator sets

Advanced Technologies to Reduce Emissions in Diesel Generators

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Nature and technology applied to reducing emissions in diesel generator sets

Reducing emissions in diesel generators has become a top priority in the power generation sector. The intensive use of electrical generators in critical sectors such as data centres, hospitals, infrastructure and industry makes it essential for these units to comply with the strictest emission limits. The combination of new technologies, alternative fuels and increasingly demanding regulations is driving a shift towards cleaner and more sustainable solutions.

Regulations and Emission Standards for Diesel Generators

Each market defines its own emission standard for diesel generators, setting the maximum permissible levels of pollutants in exhaust gases. In Europe, the Stage V standards represent the most advanced requirements, while in other regions equivalent regulations apply to internal combustion engines. These rules directly affect diesel generators, regulating emissions of nitrogen oxides (NOx), carbon monoxide (CO) and particulate matter (PM), among others.

Diesel generators remain the most reliable solution to ensure emergency power supply in critical sectors.

Complying with these regulations is not only a legal obligation but also a commitment to sustainability and a guarantee that generators provide a reliable and environmentally responsible power supply.

Main Pollutants from Diesel Generators and Their Environmental Impact

Diesel engines release several pollutants that affect both air quality and climate change:

  • Nitrogen oxides (NOx): contribute to the formation of smog and acid rain.
  • Carbon monoxide (CO): a toxic gas resulting from incomplete combustion.
  • Particulate matter (PM): microscopic particles that can harm respiratory health.
  • Carbon dioxide (CO2): a greenhouse gas and a key driver of anthropogenic climate change; diesel consumption is directly linked to CO2 emissions per litre of fuel burnt in a generator.

Reducing engine emissions is essential to mitigate these effects and secure a cleaner energy future.
Pollutant emissions and the need to reduce emissions in diesel generator sets

Reducing Nitrogen Oxides (NOx) and Particulate Matter

The most innovative technologies focus on cutting NOx and PM emissions, as these are currently the most heavily regulated pollutants. Key solutions include:

  • Advanced fuel injection and optimised internal combustion.
  • Diesel particulate filters (DPF): capture and remove particulate matter before it is released into the atmosphere.
  • Exhaust gas recirculation (EGR) systems: reduce NOx formation during combustion.

These technologies allow a generator to comply with the applicable emission standard without compromising performance.

Using After-treatment Systems to Minimise Emissions

After-treatment systems are a crucial tool for reducing emissions from combustion engines. They incorporate devices that act on exhaust gases after leaving the combustion chamber, minimising pollutants.

The combination of new technologies, alternative fuels and increasingly demanding regulations is driving a shift towards cleaner and more sustainable solutions.

The most common in diesel generators include:

  • Oxidation catalysts to reduce CO and hydrocarbons.
  • Particulate filters to trap soot.
  • Combined technologies to maximise engine efficiency.

Sustainable urban environment

How Selective Catalytic Reduction Improves Engine Efficiency

Selective Catalytic Reduction (SCR) is one of the most effective methods to cut NOx emissions. By injecting a urea solution into the exhaust system, nitrogen oxides are transformed into nitrogen and water vapour, both harmless to the environment.

In addition to reducing emissions, SCR optimises combustion, enabling the engine to operate more efficiently with lower fuel consumption, which translates into reduced emissions per litre of diesel consumed.

Alternatives to Diesel: Biofuels and Cleaner Blends

Another way to lower the environmental impact of diesel generators is through the use of biofuels and cleaner fuel blends. HVO (Hydrotreated Vegetable Oil) and biodiesel are options that significantly reduce CO2 emissions while maintaining equipment reliability.

Reducing engine emissions is essential to mitigate these effects and secure a cleaner energy future.

New-generation generators are designed to be compatible with these fuels, facilitating the transition towards more sustainable power generation.

Technology Trends for More Sustainable Generators

Technological evolution in the sector is moving towards greater integration of hybrid solutions, where diesel generators work alongside battery systems or renewable energy sources. This approach helps optimise diesel consumption, reduce engine running hours and therefore lower emissions from diesel engines.
Genesal Energy generator with technologies to reduce emissions
Furthermore, the development of more efficient engines, with advanced electronic control and compliance with the strictest emission limits, ensures that diesel generators remain a reliable solution across a wide range of applications, from 130 kW to much higher capacities.

Conclusion

Diesel generators remain the most reliable solution to ensure emergency power supply in critical sectors. Their essential role has not changed: securing energy continuity when the grid fails. What is evolving is the technology that supports them.

Each market defines its own emission standard for diesel generators, setting the maximum permissible levels of pollutants in exhaust gases.

The incorporation of after-treatment systems, selective catalytic reduction, biofuels and hybrid configurations enables modern generators to meet the most demanding emission standards for diesel generators, minimising pollutants while optimising fuel consumption.
In this way, diesel generators can support the energy transition without relinquishing their fundamental role: providing reliable power where it is most needed.

Article: Batteries and generator sets

Batteries and Energy Storage: Their Role in Modern Generating Sets

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Connected lithium-ion batteries, integration with generator sets for energy storage
In environments where energy continuity is critical, generating sets remain a guarantee of safety and reliability. In addition, their integration with Battery Energy Storage Systems (BESS) opens up new possibilities that enhance performance and sustainability.

The combination of reliable generation and intelligent storage is already a key trend for the future of distributed energy.

Far from replacing generators, BESS act as strategic allies: they make it possible to store energy produced by the genset itself or from renewable sources, reduce fuel consumption, and optimise power supply management. In this way, generating sets are evolving into hybrid solutions that are cleaner, more efficient, and aligned with Europe’s energy transition objectives.

How BESS Work When Applied to Generating Sets

BESS allow the energy generated — whether from a diesel genset, a gas unit, or a renewable source — to be stored in batteries for later use. This system acts as an energy buffer, avoiding unnecessary start-ups and reducing fuel consumption during demand peaks.
Nature and technology working together: sunlight through leaves and digital energy analysis in an industrial environment

Battery Technologies for Energy Storage

At present, three main options stand out:

  • Lithium-ion: high energy density and a greater number of charge and discharge cycles.
  • Flow batteries: more suitable for long-duration stationary applications.
  • Advanced lead-acid: an economical choice for projects with lower requirements.

The choice depends on the required storage capacity, the consumption profile, and sustainability goals.

Benefits of Battery Energy Storage for Generating Sets

  • Operational efficiency: enables gensets to run within optimal load ranges.
  • Emission reduction: by minimising the operating hours of the diesel engine.
  • Flexibility: energy can be charged and discharged according to demand.
  • Renewable support: surplus solar or wind energy can be integrated into the system.

BESS and the Energy Transition in Europe

European regulations on sustainability and emissions are driving the incorporation of storage systems. The Fit for 55 package, renewable energy directives, and the EU’s climate neutrality targets all promote the adoption of energy storage solutions as a complement to traditional generators.

BESS allow the energy generated — whether from a diesel genset, a gas unit, or a renewable source — to be stored in batteries for later use.

Generating sets with BESS make it possible to comply with energy efficiency requirements, reduce the carbon footprint, and increase competitiveness in both public and private tenders.
Bamboo forest seen from below

Energy Management with Generators and Batteries

Advanced control systems allow operators to:

  • Decide when to use stored energy and when to start the generator.
  • Avoid oversizing equipment.
  • Guarantee an uninterrupted power supply in critical environments.
  • Store energy during off-peak hours and use it during demand peaks.

Impact on Sustainability and Fuel Reduction

The integration of batteries in generators significantly reduces CO₂ emissions. This is because the generator operates fewer hours and under more stable conditions, while the storage system provides the flexibility required to meet demand.

Future Trends in Energy Storage and Generating Sets:

  • Greater integration of BESS with renewable energy in hybrid projects.
  • Standardisation of diesel+BESS hybrid systems in critical infrastructure.
  • Incorporation of hydrogen and new technologies as complementary vectors.
  • Digitalisation and remote monitoring of charge status, cycles, and performance.

Conclusion

The role of batteries for generating sets has evolved towards complete energy storage solutions. BESS not only provide efficiency and sustainability but also position gensets as part of Europe’s energy transition strategy.

Far from replacing generators, BESS act as strategic allies.

The combination of reliable generation and intelligent storage is already a key trend for the future of distributed energy.

Article: Energy resilience in critical infrastructures

Energy Resilience in Critical Infrastructure: How Distributed Generation Safeguards Operational Continuity

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Digitalized data center, example of critical infrastructure requiring energy resilience
In April 2025, a massive blackout left millions of people in Spain, Portugal and southern France without electricity for more than ten hours. The outage affected rail transport, paralysed data centres and cut power to public and private buildings, highlighting how a grid failure can have repercussions at multiple levels. It was not an isolated incident: in June 2024, a voltage collapse caused a widespread blackout in the Balkan region, leaving Albania, Montenegro, Bosnia-Herzegovina and Croatia without power. A year earlier, in 2023, an ice storm in Canada brought down thousands of power lines, disrupting supply to over a million people and forcing hospitals, water treatment plants and emergency services to operate for days solely on backup systems.

Adequate reserves and priority replenishment contracts are part of any business continuity strategy.

These kinds of events demonstrate that critical infrastructure such as hospitals, data centres, transport systems or control hubs cannot afford power outages without compromising safety, the economy and, in many cases, human lives. Ensuring their continuous operation requires solutions that combine reliability, rapid response and operational autonomy. In this context, distributed generation emerges as an essential tool: it enables energy production closer to the point of consumption, reduces dependency on the grid, and increases resilience and capacity to anticipate failures or external disruptions—an area in which Genesal Energy has solid experience developing bespoke solutions for strategic sectors.

Distributed Generation as a High-Availability Solution

Producing electricity at the point of consumption—or in its immediate vicinity—offers decisive advantages in environments where service continuity is non-negotiable, from reducing transmission losses to enabling island mode operation and tailoring technology to the specific characteristics of each facility. These systems therefore strengthen the ability to respond instantly to any interruption.

In critical infrastructure, backup systems are usually based on diesel or gas gensets, often combined with energy storage and, increasingly, with renewable generation. These configurations are designed to come online within seconds of detecting a failure and, in particularly sensitive applications, incorporate N+1 redundancy: an additional unit capable of carrying the full load if the main unit goes out of service.

Ensuring stable operation over extended periods requires attention to factors such as fuel storage capacity, engine efficiency, and the thermal and acoustic management of the installation. In hospital environments, for instance, it is common to install tanks that guarantee at least 48 hours of autonomy and control systems that prioritise power to essential areas, thereby ensuring continuous availability during crises.
Macro detail of a green leaf symbolizing sustainability

Design and Operation: Key Factors

The starting point for any distributed backup generation system is a detailed analysis of the critical load. This defines which equipment must remain powered, the maximum expected demand during peak periods, the duration for which supply must be maintained, and the appropriate level of redundancy. A medium-sized hospital, for example, may concentrate most of its critical load in operating theatres, intensive care units and climate control systems for sensitive areas, with demands exceeding one megawatt of power.

These systems therefore strengthen the ability to respond instantly to any interruption.

Planned maintenance is a key factor in ensuring availability. It includes periodic inspections of starting systems, monitoring battery condition, checking electrical connections and verifying fuel quality. In critical installations, these tasks are reinforced with regular live load tests to confirm switching times, voltage and frequency stability, and coordination with other electrical systems. Increasingly, remote monitoring and predictive maintenance are integrated—tools that Genesal Energy employs to anticipate incidents and optimise operation.

Integration with Renewables and Storage

Integration with renewable sources and storage is becoming increasingly common. A hybrid system combining solar PV, batteries and a genset can optimise fuel consumption and extend autonomy, particularly useful in situations of prolonged isolation.

Coordination between these sources is managed by control systems that prioritise efficiency while guaranteeing power availability at all times. This strategy not only reduces emissions but also helps extend the service life of thermal units by reducing idle or low-load operating hours. In line with its sustainability commitment, Genesal Energy incorporates ecodesign-certified solutions (ISO 14006) and alternative fuels such as HVO, which can cut the carbon footprint by up to 90% compared to fossil diesel.

Challenges and Opportunities in the Spanish Context

The deployment of distributed generation solutions for backup in critical infrastructure in Spain faces several challenges. One is updating regulations to facilitate the integration of renewables and storage while maintaining the required reliability standards. Another is the modernisation of the installed fleet: many units currently in operation consume more fuel and emit more than today’s technologies. In some cases, replacing them with more efficient models can reduce specific consumption by over 15% and improve dynamic response to sudden load changes.

Fuel supply logistics is another key factor. Adequate reserves and priority replenishment contracts are part of any business continuity strategy. In urban environments, space limitations or environmental restrictions can affect storage capacity, driving the adoption of solutions such as external modular tanks or low-emission fuels like HVO.

Aerial view of an industrial plant, example of critical infrastructure

Overcoming these challenges will not only strengthen resilience but also advance decarbonisation and energy independence. Genesal Energy’s experience shows that the most effective solutions combine proven technology with meticulous planning in operation, logistics and maintenance, ensuring the operational continuity of critical installations while aligning with the objectives of the energy transition.