A bespoke 1,850 kVA solution to protect the cold chain at a major logistics platform in Getafe

At a food distribution platform, refrigeration is not merely an operational consideration: it is central to the entire business. A power outage at the wrong time can put tons of products at risk, disrupt traceability and bring goods reception and dispatch operations to a standstill.

For a major Spanish supermarket chain, managing this risk effectively required an emergency generator set capable of meeting the facility’s demanding requirements.

Genesal Energy has designed a complete solution encompassing not only the equipment itself, but also the installation engineering, its integration into the building and the design of the exhaust gas system.

Available space as the starting point for the engineering design

The logistics centre’s plant room had significant space constraints, making the installation design one of the main challenges of the project.

To address this limitation, we developed a 1,850 kVA open generator set mounted on a fully bespoke base frame, designed to fit the available space without the need to dismantle any components during transport. This solution simplified both logistics and installation work.

The base frame incorporates a 1,000-litre fuel tank that provides the autonomy required for this application. The power and control panels were also integrated into the base frame, making optimum use of the available space while maintaining full accessibility for maintenance work.

Complete integration: from the generator set to the building

Our involvement went beyond supplying the generator set, as we also developed the complete installation engineering.

We designed the exhaust gas system and collaborated on defining the acoustic attenuation solution. As part of this work, our technical team designed the ventilation attenuators, which were subsequently manufactured by the customer.

Before delivery, the generator set underwent the corresponding FATs (Factory Acceptance Tests) at our facilities, attended by both our direct customer and the end customer. During the tests, single-step load impacts of up to 65% were applied to verify the generator set’s correct performance and its response capability under the installation’s operating requirements.

This project reflects our approach to every challenge: developing customised solutions that combine engineering, manufacturing and technical expertise to meet the specific needs of each installation.

Key features

• Special 1,000-litre fuel tank integrated into the base frame.
• Power cabinet with a 3,200 A circuit breaker, differential protection and busbars for connection to the customer’s power cables.
• Protective enclosure for two 225 Ah batteries.
• Control panel fitted with a ComAp InteliLite AMF 25 IL4 controller.
• Pump-assisted engine heating system to maintain the engine at the optimum temperature for starting and immediate load acceptance.
• Electronically governed engine.
• Exhaust silencers with 25 dB attenuation.