High-power Genesal Energy generator for a logistics center in the UK

Guaranteed Power for a Major Logistics Hub in the United Kingdom

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In some sectors, time is everything and even a brief interruption can lead to millions in losses.

This is especially true for logistics hubs. Genesal Energy knows this well, because we work daily with industries where energy is far more than just a resource – it’s the foundation upon which operations, logistics, and business are built.

One of our latest projects took place in an environment where continuity is critical: a 60,000-square-metre logistics centre serving a range of e-commerce and distribution companies. In this type of facility, electricity powers IT servers, automated machinery, robotic systems, and security controls. Our engineering team got to work to create a robust, efficient and fully tailored solution.

To meet the requirement, we designed a soundproof generator set in a 5000M canopy, with the engine and alternator directly coupled on a steel base frame. One of the key elements was autonomy: the unit includes a 900-litre integrated fuel tank, providing 4.5 hours of uninterrupted operation. In addition, a rubber anti-vibration system was installed to improve durability and reduce wear.

As in all our projects, safety was a top priority. We included protective guards on moving and hot parts, emergency stop buttons, and an external Link Box to facilitate both control and power connections.

Silent and Highly Reliable Technology

The installed set fits a GSI 650 silencer model, known for its low noise level (-30 dB) and other high-quality components, such as a Deep Sea DSE7320 MKII control panel and a 1600 A circuit breaker. The system is supported by two Tudor TC1853 185 Ah batteries, ready to respond in any scenario.

This project perfectly reflects what Genesal Energy stands for – a company that listens, analyses, and designs real, efficient, and long-lasting solutions. Because we understand our clients’ risks.

The Engineering Solution

A soundproof generator set was developed in a 5000M canopy, featuring a directly coupled engine-alternator mounted on a steel base frame. The integrated 900L fuel tank offers 4.5 hours of autonomy. Vibrations between the frame and monoblock were dampened using rubber anti-vibration mounts. Safety features include guards on hot and moving parts, emergency stop buttons, and other components to ensure safe operation.

Main Features

  • Design: Monoblock engine-alternator in 5000M soundproof canopy.
  • Integrated 900L baseframe fuel tank with a leak tray.
  • Silencer model: GSI 650 (-30 dB).
  • Deep Sea DSE7320 MKII control panel.
  • 1600 A circuit breaker.
  • Batteries: 2x Tudor TC1853 (185 Ah).
Generator for the industrial sector

Uninterrupted production thanks to Genesal Energy in the industrial sector

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Genesal Energy has developed a new project for a company in the industrial sector in the UK, guaranteeing a constant power supply in a plant where operational continuity is key to profitability.

The generator was supplied, installed and commissioned through Ingram Installations Ltd., ensuring the equipment was ready to operate under the highest reliability standards.
When production cannot stop, power must respond. Any disruption to the power supply can result in loss of production, material damage and even contractual penalties. That is why having a robust and secure back-up system is a strategic need.
Genesal Energy generator installed outdoors at an industrial facility in the UK

Our Engineering solution

Our engineering department designed a soundproofed generator set, mounted on a steel frame with direct coupling between engine and alternator. The system includes an integrated 950 litre tank with a liquid collection tray, providing an autonomy of up to 8 hours of continuous operation.

An external linkbox was installed in a closed cabinet, facilitating the connection of power and control cables in complete safety for the operators.

To optimise performance and durability, anti-condensation heaters were incorporated into the alternator, an anti-vibration system with rubber mounts, and protective mesh in the openings to prevent the entry of animals.

Genesal Energy generator installed outdoors at an industrial facility in the UK
In addition, an external linkbox was installed in a closed cabinet, facilitating the connection of power and control cables in complete safety for the operators. The generator also includes all the required protection systems: emergency stop mushrooms, protections for moving parts and hot elements, always guaranteeing safe operation.

Features

  • Construction: 5000 Canopy
  • Tank: 950L integrated in baseframe
  • Silencer model: GSA 650 (-30dB)
  • Deep Sea DSE7310 MKII control panel
  • Installation of anti-condensation resistors in the alternator
  • External connection linkbox

Genesal Energy designs customised solutions key to industrial productivity for a chemical plant

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Genesal Energy knows that energy is the engine that drives industry, and we work to ensure that it never stops.

We believe that it is essential to design generating sets that provide solutions for different industrial sectors.

To guarantee operational continuity, energy security and the capacity to respond to any type of contingency, it is essential to have equipment that guarantees a constant supply of energy. We have designed and supplied a customised generator set for a chemical plant located in the Sabón Industrial Estate, Northern Spain, reinforcing its capacity to guarantee production and maintain its competitive advantage in a demanding market.

This chemical plant operates during all three shifts, making constant power availability a critical factor. Our engineering team designed a generator set that can work in parallel with the power grid, minimising the impact of possible power failures and eliminating the risk of the dreaded ‘zero-crossing’, which could stop the machines and cause time and productivity losses.

Considering that this factory is located in a marine environment, the equipment was designed with specific features to guarantee its durability and optimum performance, with a soundproofed canopy, a 700-litre tank for greater autonomy and C5M paint surface treatment in accordance with ISO12944 standards.

A marinised alternator has been also included, specially prepared for high salinity conditions, to which an advanced ComAp InteliGen4 200 control panel has been added, designed to manage operations in parallel with the grid.

A key service for competitiveness in the industrial sector

In a market where efficiency and operational continuity are crucial, having a backup generator set not only protects production processes, but is also a differentiating factor that ensures business competitiveness.

Power outages not only affect immediate production but can also compromise the ability to meet delivery deadlines, impact product quality and ultimately customer satisfaction.

Our engineering solution

A unit was designed that, firstly, could fulfil the function of working in parallel with the grid to guarantee the minimum downtime impact in the event of a failure of the factory’s main supply. Then the parts of this equipment were manufactured with a special surface treatment as it was exposed to a marine environment (marinised canopy and alternator).

Features

  • Supply: 3900mm Soundproofed Canopy.
  • Tank: 700L base frame integrated.
  • Control panel: ComAp InteliGen4 200 for parallel operation.
  • Surface paint treatment according to ISO12944 – C5M.
  • Marinised alternator.
  • Motorised Circuit Breaker.

Uninterruptible Power, the Key to Industrial Success in the Heart of Guanajuato

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Genesal Energy continues to strengthen its commitment to the industrial sector, offering power backup solutions adapted to the most demanding market needs. On this occasion, it has supplied a state-of-the-art open generator set for an automotive manufacturing plant in Guanajuato, Mexico. This equipment will provide contingency power to a new assembly line for painting, one of the most critical processes in the automotive production chain.

Backup generator sets in factories are not only a strategic advantage, but essential to ensure operational continuity. In high-demand sectors, such as the automotive industry, where every minute of production counts, having a backup power source prevents unplanned shutdowns that could lead to major economic losses and delays in the supply chain. In addition to protecting the investment, a generator set ensures that quality and safety standards are maintained even in the event of power failures.

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Power to ensure operational continuity

Thanks to our genset, uninterrupted operation of the assembly line ensures the workflow is not affected by possible electrical failures. It is installed in a hangar near the paint line and has been designed to meet the customer’s main need: long autonomy. This is achieved by means of an independent 3000 litre double-walled steel tank, designed to provide an energy reserve in accordance with the specific requirements of the installation.

The generator set supplied in Guanajuato stands out for its advanced specifications, which ensure its ability to operate reliably in demanding industrial conditions. With this project, Genesal Energy reaffirms its commitment to accompany the automotive industry in its growth, offering high quality energy solutions.

Features

  • Open genset with independent control cabinet, it can be unbolted and placed close to the generator set.
  • Large self-supporting power cabinet with the possibility of top entry of 10 power cables of 300mm^2 by the end customer.
  • 3000 litres independent double-walled (Steel-steel) fuel tank.
  • Fuel flow meter installed in control cabinet on independent display.
  • Critical -40 dB(A) silencer.
  • Analogue oil temperature sensor.
  • Due to the installation at high altitude above sea level, precise calculations of the power of the unit at the final location.

 

Genesal Energy secures supply at Europe’s leading engineering research centre

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Investment in innovation & research ensures the competitiveness of a company.

This is often materialised in a research centre or campus which search for the best suppliers and solutions.

Genesal Energy has designed a solution to secure the power supply of Europe’s largest enclosures engineering space. These 29,000 sq. metres premises are devoted to the research of customised enclosures for large buildings around the world, with a team of 350 engineers and architects.

Our solution was a 250 kVA generator set with an autonomy of more than 6 hours, vibration isolation and a silent engine that does not interfere with advanced test benches or thermal and acoustic performance tests.

Genesal Energy has eliminated the risks of power supply instability, power cuts or voltage variations, ensuring the progress of research.

Our engineering solution: research center generator

An open generator set with an engine-alternator direct coupling on a steel bedplate. The integrated 350 L tank provides an autonomy of 6.8 hours. Vibration isolation between the base plate and the monoblock was achieved by means of a rubber anti-vibration system. The integration of protections for moving parts and hot parts has also been taken into account, as well as emergency stop buttons and other elements necessary to operate the unit safely.

Features

  • Supply: 2,800mm bedplate.
  • Tank: 350 L integrated in the bedplate.
  • Silent model: GSA 365 (-25dB).
  • Control panel: ComAp InteliLite.

 

 

 

Clean energy with Stage V units to guarantee supply to a degassing plant in the Basque Country

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Environmentally friendly, less polluting and silent.

Our Stage V generator sets have been manufactured to keep gas emissions at bay and that comply with the demanding European Regulations.

As part of our sustainability strategy and in the search for the best solutions within energy transition, our Engineering Department has just designed a Stage V generator set for a mobile degassing container.

The task was to supply emergency power to a degassing plant in the Basque Country so that in the event of a grid failure there would be no problems. “Providing emergency power supply via a Stage V degassing plant generator set, we guarantee the correct operation of the plant, and we help the environment”, says Genesal Energy’s engineering department.

Our proposal

Our Engineering Department developed an open skid genset with a 300L tank capacity where the various maintenance elements, automatic, control panel and filling points (both for diesel tank and urea tank) are located to the left of the genset. Special attention was also paid to the protection of hot parts, as well as the location of the different elements required by the Stage V groups.

Degassing plant generator set features

  • 2,200mm Open Skid Generator Set
  • Standard 300 L tank.
  • Reduced dimensions to adapt to the customer’s container.
  • Control panel and switch located on the same side.
  • Elevated diesel fuel inlet.
  • ComAp InteliLite4 AMF 25 controller.
  • Oversized 135 kVA alternator to guarantee starting of motors and compressors.

Emergency Power for Phosphates Treatment Plant in El Jadida, Morocco

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The project has been designed for one of the most important companies in the engineering and constructin sector, with headquarters in Marseille (France).

Situated 80KM south of Casablanca and 17Km from El Jadida is the Jorf Lasar industrial complex, a phosphates treatment plant which Genesal Energy has supplied with 3 specially designed gensets for emergency back-up.

The plant whose installations cover an area of 1,700 hectares began its production in 1986 and its numbers are quite impressive: the recuperation of 2 million tonnes annually of P2O5 in the form of phosphorus acid.

Genesal Energy has supplied this elaborate facility in Morocco with a genset island comprising of identical generators for outdoor use (3 units at 400V/50Hz containerised with a control system) designed to work in parallel or if necessary individually. Five circuit breakers make up the switchgear.

In detail

As with every project undertaken by Genesal, the control system designed for this phosphate treatment plant was managed to the tiniest detail:

  • If the gensets are operational, they can be synchronised, either with the output switch of each genset or with the coupling point, therefore reducing the number of movements required by the switches in case of changes in the operational format.
  • If a generator is stopped, the circuit breaker is disabled to avoid damage from unwanted power inputs from external busbars
  • If the client has not indicated that a connection panel should receive an electrical feed, the incoming power cabinet circuit breaker will not be permitted to close (not even manually), in order to avoid short circuits caused by external voltage not from the actual genset island.