The future of generator sets: More sustainable and connected

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In an increasingly complex energy landscape, where electrification, renewable energies and the need for continuous power supply coexist even in the event of grid failures, generator sets play a decisive role. Their evolution in terms of sustainability, efficiency and connectivity is redefining their presence in critical sectors and in environments where generating electricity in an environmentally responsible way has become an essential requirement. This article analyses how the sustainable generator set is evolving, its role in the energy transition and the technologies that will shape its future.

The role of generator sets in the energy transition

The transition towards clean energy has driven a profound change in the way energy is produced. As the penetration of renewable energy increases within the energy mix, so too does the need for backup systems capable of guaranteeing continuous power when environmental conditions prevent renewable sources from fully meeting demand.

The future of generators lies in further promoting hybrid solutions, alternative fuels and technologies that make better use of renewable energy.

In this context, the generator set remains a strategic energy source. Its role is no longer limited to acting as emergency equipment: today it is integrated as part of the energy ecosystem of industries, hospitals, data centres and critical infrastructures, providing operational flexibility and security. For companies and public administrations, ensuring energy supply in the event of interruptions or demand peaks is essential, and generators are becoming a key tool in this new hybrid and dynamic model.
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How to reduce environmental impact in power generation

Sustainability has become a central pillar in the design and manufacture of equipment intended to generate electricity. The need to reduce the greenhouse effect and to develop increasingly environmentally friendly equipment has led to new approaches aimed at creating generator sets adapted to the environmental requirements of the future.
This progress involves action on several fronts: improving engine efficiency, optimising combustion systems, reducing energy losses and using materials with a lower environmental impact. In addition, eco-design principles and the identification of environmental aspects at each stage of the generator’s life cycle help minimise its environmental footprint, from initial design through to on-site operation.
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Increasingly stringent emissions regulations are also accelerating the development of cleaner generators, capable of operating with lower consumption and reduced pollutant emissions. As a result, manufacturers are investing in technologies that reduce emissions without compromising the operational reliability that characterises these systems, while maintaining optimal performance.

Use of alternative fuels and renewable energies

The path towards a sustainable generator necessarily involves fuel diversification. The introduction of HVO (hydrotreated vegetable oil), advanced biofuels or even blends with green hydrogen opens up a range of solutions to progressively replace traditional fossil-based fuels.

Efficiency is one of the main indicators of technological progress in generator sets.

Renewable fuels allow generators to operate with a significantly lower carbon footprint and offer additional advantages: they require no major modifications to many modern diesel engines and maintain the operational stability needed for critical environments. These alternatives are complemented by the growing drive to integrate generator sets into hybrid systems based on renewable energy.
Ongoing R&D in this field is enabling generators to operate as part of a flexible energy system in which sustainable fuels, energy storage, power electronics and renewable energy sources coexist to optimise every kilowatt consumed.
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Integration of generator sets with solar panels and wind energy

Infrastructures that combine generators with solar panels or wind farms are no longer a trend, but a rapidly expanding reality. The combination of generators and clean energy sources makes it possible to reduce fuel consumption, extend autonomy and lower overall system emissions.
In off-grid applications, such as remote areas not connected to the electricity grid, hybridisation is essential to produce energy efficiently. Solar panels provide daytime generation, wind energy complements supply at variable times, and the generator acts as a backup when weather conditions do not allow demand to be fully met. This model improves overall system performance and significantly reduces dependence on fuel.
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The result is a sustainable power generator capable of operating in complex scenarios, offering greater autonomy and optimised control of available resources.

Technological advances to improve efficiency and reduce emissions

Efficiency is one of the main indicators of technological progress in generator sets. The development of more advanced engines, high-pressure injection systems, optimised turbochargers and exhaust after-treatment systems has enabled modern generators to consume less fuel and emit fewer pollutants to meet the same energy requirements as previous generations.

The transition towards clean energy has driven a profound change in the way energy is produced.

Improvements are not limited to the engine itself: electronics play a decisive role in load management, start-up optimisation, avoidance of unnecessary consumption and adjustment of operation to real demand. In parallel, energy storage solutions make it possible to combine batteries and generators to further reduce consumption when demand is low.
Continuous innovation in these areas helps consolidate the sustainable generator set as a more efficient solution, ready to meet future environmental standards.
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Connectivity and intelligent monitoring in power generators

Connectivity has transformed the way data from modern generators is managed and interpreted. Remote monitoring systems allow real-time supervision of operating parameters, alarms, consumption, emissions and load trends. Thanks to this connectivity, equipment benefits from more effective predictive maintenance, higher availability and lower operating costs.
Digitalisation turns the generator into an active element within the energy ecosystem, capable of communicating with other equipment, integrating into management platforms and supporting data-driven technical decisions. For industries that require continuous power, this intelligence adds security, reliability and efficiency.

Trends and the future of generator sets in a sustainable world

The future of generators lies in further promoting hybrid solutions, alternative fuels and technologies that make better use of renewable energy. The trend is clear: to develop equipment that reduces environmental impact without sacrificing the reliability that has always defined the sector.
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The combination of technology, sustainability and connectivity is shaping a new standard in which the generator becomes a flexible, optimised element capable of integrating with clean energy sources to deliver efficient, stable power supply aligned with the demands of a more sustainable world. In this scenario, companies that invest in innovation and environmentally responsible approaches will lead the transformation towards a safer and more resilient energy system.

Simplifying without dismantling: the Omnibus Package and the future of European ESG regulation

In recent years, the European Union has rolled out one of the most ambitious sustainability regulatory frameworks in the world.

Directives such as the CSRD, the CSDDD and the CBAM have placed companies at the heart of the ecological and social transition, assigning them a key role in emissions reduction, transparency and due diligence throughout the value chain. This regulatory expansion, however, has been accompanied by growing criticism from Member States and the business sector, which have warned about the complexity of the resulting framework, the overlap of obligations and its impact on European industrial competitiveness.

Sustainability cannot be built solely on increasingly complex regulatory frameworks, but rather on clear, coherent and applicable regulations.

It is in this context that the Omnibus Package has emerged: an initiative by the European Commission designed to review and adjust this regulatory framework without dismantling it. Far from constituting a single piece of legislation, the Omnibus acts as a cross-cutting amending instrument, introducing coordinated changes to several key components of the European ESG framework with the aim of aligning regulatory requirements with companies’ actual capacity to comply and with their potential impact.

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Presented in February 2025, the Omnibus Package has progressed over the past year through an intense process of institutional negotiation. The positions of the Council and the European Parliament have gradually converged, leading to political agreements that significantly reshape both the scope and the intensity of corporate sustainability obligations in the European Union, particularly through amendments to the CSRD and the CSDDD.

CSRD: fewer companies in scope, greater focus on large organisations

The Corporate Sustainability Reporting Directive (CSRD), which replaces and expands the former Non-Financial Reporting Directive, was originally designed to extend sustainability reporting to tens of thousands of European companies. The Omnibus Package introduces one of its most significant changes here by redefining the applicability thresholds, with the aim of concentrating the most complex obligations on organisations with the greatest potential impact and the greatest capacity to generate comparable and verifiable information.

As a result, the obligation to report under the CSRD is now limited to companies with more than 1,000 employees and annual turnover exceeding €450 million. In the case of third-country companies, the directive applies where turnover generated within the European Union also exceeds this threshold.

The Omnibus Package represents a step in the right direction, opening the door to a more functional regulatory framework focused on the effective reduction of unnecessary burdens.

The Omnibus also introduces technical adjustments to the practical application of the CSRD, particularly with regard to the level of reporting detail and information from the value chain. The European Sustainability Reporting Standards (ESRS) remain the technical framework, but their application is more precisely defined, allowing data collection to be limited to those parts of the value chain where there is genuine influence or where clear material risks have been identified.
This approach has direct implications for the protection of small and medium-sized enterprises, which under the original design of the CSRD could have been subject to disproportionate obligations as suppliers to large companies. By linking information requests to materiality and actual influence, the Omnibus reduces the cascading effect and limits the systematic transfer of regulatory burdens to SMEs. It also explicitly recognises the possibility of using estimates, sectoral data or aggregated information where reliable primary data cannot be obtained, provided that this choice is duly justified.
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At the same time, the Omnibus Package strengthens coherence between the CSRD and the EU Taxonomy, clarifying that the obligation to report under the CSRD does not automatically entail reporting with the same level of detail on taxonomy alignment. The scope of Taxonomy-related reporting must be aligned with the financial materiality of the company’s activities and their effective fit with the defined technical criteria.
Within this framework, the principle of double materiality remains a structural pillar of reporting, but its practical role as a prioritisation tool is reinforced. This allows companies to document why certain indicators or disclosures are considered relevant and others are not, avoiding a uniform approach that would require reporting information of limited significance from an impact or financial risk perspective.

CSDDD: more limited and gradual due diligence

The Corporate Sustainability Due Diligence Directive (CSDDD) has been one of the most controversial elements of the European ESG framework, both in terms of its scope and its legal implications. The Omnibus Package introduces substantial changes here, starting with a very restrictive redefinition of its personal scope of application compared with the directive’s original design, which covered companies with at least 1,000 employees and €450 million in turnover. The new framework limits its application to companies with more than 5,000 employees and global turnover exceeding €1.5 billion.

The Omnibus acts as a cross-cutting amending instrument, introducing coordinated changes to several key components of the European ESG framework.

Alongside this adjustment, the Omnibus redefines the material scope of due diligence, limiting enhanced obligations to established business relationships and to areas where adverse risks have been identified and are reasonably foreseeable. This enables companies to prioritise actions and focus resources, rather than deploying uniform controls across the entire value chain.
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The Omnibus also removes the explicit obligation to adopt binding climate transition plans as part of CSDDD compliance and thoroughly revises the civil liability regime, limiting automatic exposure to claims and linking liability to the reasonableness of the measures adopted. The sanctions regime is also adjusted, setting caps at around 3% of global turnover and reinforcing the principle of proportionality.

From an institutional perspective, these changes are justified as a means of ensuring the directive’s legal, operational and economic viability. However, they have attracted criticism from social and environmental organisations, which argue that the reduction in scope and obligations may weaken its transformative potential.

Taxonomy and CBAM: continuity with technical adjustments

Although the main focus of the Omnibus Package has been on the CSRD and the CSDDD, the initiative also introduces relevant adjustments to other key instruments of the European sustainability framework, particularly the EU Taxonomy and the Carbon Border Adjustment Mechanism (CBAM), with the aim of improving internal coherence and reducing unnecessary administrative burdens.

In the case of the EU Taxonomy, the Omnibus does not alter the technical criteria for classifying sustainable economic activities, but it does more precisely redefine the scope and intensity of the associated reporting obligations. The new approach clarifies that not all companies required to report under the CSRD must do so with the same level of detail in relation to the Taxonomy.
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In practice, a more selective and proportionate application of taxonomy reporting is introduced, linking the level of information required to the financial materiality of activities and their effective alignment with the defined technical criteria. This translates into greater flexibility when reporting key indicators (such as aligned CAPEX or OPEX) where the company’s activity cannot be clearly classified as eligible or aligned, or where such information is not financially material. The aim is to avoid duplication with the CSRD and reduce the production of complex information with limited analytical value.

The European Sustainability Reporting Standards (ESRS) remain the technical framework, but their application is more precisely defined.

As for the CBAM, its basic architecture is maintained as an instrument designed to prevent carbon leakage and ensure more balanced competitive conditions between European and non-EU producers. However, the Omnibus Package introduces technical and operational adjustments intended to facilitate its implementation, particularly with regard to administrative requirements for importers, the collection of data on embedded emissions and coordination with other EU climate instruments. These adjustments seek to improve the mechanism’s practical applicability without altering its core objective or environmental rationale.

Simplification or rollback?

The debate surrounding the Omnibus Package has often been framed in terms of simplification versus ambition. However, a technical reading of the set of amendments points to a different issue: the actual effectiveness of the regulatory framework. After several years of very intense regulatory expansion, the Omnibus responds to the need to correct dysfunctions identified in the practical application of certain obligations, particularly those that have generated duplication, high administrative burdens or limited results in terms of environmental and social impact.
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From this perspective, the adjustments introduced do not necessarily imply abandoning the objectives of the European Green Deal, but rather an attempt to redirect regulatory efforts towards areas where they can generate a genuine transformative effect, avoiding a situation in which excessive complexity ultimately dilutes effectiveness or diverts resources towards purely formal compliance. The challenge will be to ensure that simplification does not lead to the creation of new instruments that are equally complex or impractical, reproducing under different formats the very problems now being addressed. Even so, the Omnibus Package represents a step in the right direction, opening the door to a more functional regulatory framework focused on the effective reduction of unnecessary burdens.

The Omnibus Package has progressed over the past year through an intense process of institutional negotiation.

From the perspective of Genesal Energy, this approach is particularly relevant for the European industrial fabric. Sustainability cannot be built solely on increasingly complex regulatory frameworks, but rather on clear, coherent and applicable regulations that allow companies to concentrate resources on the real improvement of their processes, products and value chains. When administrative burdens exceed operational capacity, there is a risk that sustainability becomes a purely documentary exercise, disconnected from the industrial transformation it is meant to drive.
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Ultimately, the success of the Omnibus Package will not be measured solely by the number of obligations adjusted, but by its ability to strengthen the competitiveness of European industry while keeping long-term sustainability objectives firmly in sight. It is within this balance between ambition and applicability that much of the future of the European regulatory model — and its capacity to effectively support the transition towards a more sustainable economy — will be determined.

Hybrid Solar Systems with Diesel Generators for Remote Areas

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.

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

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.

How to Calculate the kVA Required for a Generator

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.

Advanced Technologies to Reduce Emissions in Diesel Generators

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.

Batteries and Energy Storage: Their Role in Modern Generating Sets

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.

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

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.

Modular Generator Design for Large-Scale Projects

Genesal Energy factory with modular generator sets under assembly

What is Modular Generator Design?

Modular generator design has become one of the most efficient solutions to meet the growing energy demands of large-scale projects. Unlike conventional generators, which are designed as independent and fixed units, modular systems allow several units to be interconnected to operate together as if they were a single high-power installation. This concept offers greater flexibility, scalability, and reliability, especially in sectors where the continuity of power supply is critical. For this reason, more and more large generator manufacturers are offering modular configurations tailored to different scenarios.

Advantages of Modular Systems in Large Projects

Modular generators provide benefits that go far beyond installed capacity. Key advantages include:

  • Progressive scalability: additional modules can be added as demand increases.
  • Risk reduction: if one module fails, the others remain in operation, ensuring uninterrupted power supply.
  • Cost optimisation: there is no need to oversize the system from the outset, as the investment is adjusted to the actual demand at each project stage.
  • High availability: modular systems make it possible to schedule maintenance without shutting down the entire operation.

These features make modular design a strategic alternative for industrial plants, major infrastructure, and international projects requiring large-scale energy solutions.

How Modules are Integrated into Power Generation

Module integration is achieved through advanced control systems that automatically synchronise the generators. This technology allows different modular generators to operate as a single power plant, managing loads efficiently.

Modular systems allow several units to be interconnected to operate together as if they were a single high-power installation.

Leading manufacturers implement digital platforms capable of real-time monitoring of consumption, load, and module performance. This ensures greater grid stability, even in complex environments such as hospitals, refineries, or data centres.

Flexibility and Scalability in Power Demand

One of the greatest advantages of modular design is its ability to adapt to fluctuating and even intermittent demand. Having several units to meet power requirements makes it easier to operate each generator at its optimum performance point. Intelligent coordination between modules enables more efficient operation, with lower fuel consumption and reduced wear on equipment, cutting both environmental impact and maintenance costs.

Building construction with crane on site, example of projects requiring modular generator sets
In construction projects, energy requirements vary depending on the phase of work, while in critical industries such as mining or oil and gas, consumption peaks are often unpredictable. Modular generators make it possible to size the energy system precisely, increasing or reducing capacity within hours. This scalability ensures a rapid response to any scenario, optimising resources and reducing operating costs.

Maintenance Optimisation and Reduced Downtime

Maintenance is another strong point of modular design. Unlike a plant based on a single large generator, modularity allows maintenance and repair work to be carried out in phases, while other modules remain operational to guarantee the power supply.

This translates into:

  • Reduced downtime.
  • Greater safety in critical sectors such as telecommunications, healthcare, or defence.
  • Optimised technical resources, as preventive maintenance can be scheduled without affecting service continuity.

As a result, manufacturers specialising in large-scale projects ensure not only the required power but also maximum system availability.

Applications of Modular Design in Industrial and Critical Sectors

The modular design of generators is especially valuable in sectors where uninterrupted power is non-negotiable. Examples include:

  • Data Centres: this new way of addressing energy resilience enables the progressive commissioning of complex projects and is fully compatible with standard redundancy schemes (Tier I–IV) through specialised and customised engineering.
  • Hospitals and healthcare: ensure uninterrupted power supply for operating theatres, intensive care units, and life-support systems.
  • Oil and gas industry: in refineries and plants where any interruption entails risk and high restart costs.
  • Remote projects: often with variable energy demands, these benefit greatly from modular scalability.
  • Critical infrastructure: airports or power plants require reliable and flexible solutions.
  • Construction and infrastructure: from large-scale civil works to temporary facilities, modules adapt to the different stages of a project.

In all these sectors, modular design provides not only power but also reliability, cost optimisation, and security.
Hospital and data center as examples of critical sectors

Technology Trends to Improve Modular System Efficiency

The future of modular generator design is driven by technological innovation. Main trends include:

  • Digitalisation and remote monitoring: real-time control via digital platforms, ensuring optimal efficiency of each module.
  • Integration with renewable energy: hybrid systems combining diesel or gas generators with batteries and renewables enhance project sustainability.
  • Alternative fuels: biofuels and HVO (hydrotreated vegetable oil), which reduce the carbon footprint without altering engine performance. Although exhaust emissions remain the same, lifecycle calculations lower the overall climate impact.
  • Eco-design and energy efficiency: reducing environmental impact and complying with international standards are shaping the sector’s evolution.

In this context, large generator manufacturers are developing increasingly efficient, reliable solutions tailored to the demands of the energy transition.

Conclusion

Modular generator design has become a strategic response to the energy needs of large-scale projects. Its flexibility, scalability, and operational efficiency, combined with its ability to guarantee service continuity, make it a key solution in critical and industrial sectors.

Modular generators make it possible to size the energy system precisely, increasing or reducing capacity within hours.

With the advancement of digitalisation, sustainable fuels, and renewable integration, modular generators are set to lead the future of large-scale distributed generation, delivering power, reliability, and sustainability in a single system.

From Regulation to Innovation: The Decarbonisation Pathway of Gensets

Green leaf lit by the sun against a blue sky background

On the anniversary of the adoption of the Sustainable Development Goals, it is timely to review how strategic technologies such as gensets are being transformed to align with the 2030 Agenda. The transition towards a low-carbon economic model, reflected in goals such as SDG 7 (affordable and clean energy), SDG 9 (industry, innovation and infrastructure), SDG 12 (responsible consumption and production) and SDG 13 (climate action), is radically reshaping the framework in which distributed generation technologies operate. The increasing penetration of renewable sources such as wind and solar power adds complexity to the electricity system and raises resilience requirements. In this context, emergency gensets—traditionally regarded as marginal backup equipment—are becoming a critical element for energy security and operational continuity.

Decarbonisation of the sector must therefore be based on three main pillars: the gradual substitution of fossil diesel with renewable fuels, the development of hydrogen-based solutions, and the application of circular economy principles in design and manufacturing.

Their role is crucial in hospitals, data centres, telecommunications, transport and essential services, where they ensure supply in the event of grid failure. Although their annual operating time is limited—around ten hours on average in Europe, including periodic testing—and therefore their cumulative impact is small compared to other generation sources, achieving a climate-neutral economy aligned with the SDGs also requires these units to evolve. For this reason, the industry is working on the incorporation of renewable fuels, hydrogen-based solutions and ecodesign principles, so that gensets can maintain their strategic role while effectively reducing their environmental footprint.

Interior of a space covered with vegetation

Regulatory Framework: Stage V and the Outlook for Stage VI

Current EU legislation on emissions for internal combustion engines intended for non-road mobile machinery is mainly based on Regulation (EU) 2016/1628, known as Stage V. Its implementation, phased in between 2019 and 2021 depending on power ranges, broadened the spectrum of regulated capacities and substantially tightened the emission limits for NOx, particulates (PM), hydrocarbons (HC) and carbon monoxide (CO).

Stage V introduced the general requirement to use after-treatment technologies such as selective catalytic reduction (SCR), diesel oxidation catalysts (DOC) and diesel particulate filters (DPF). It also imposed the use of advanced electronic control systems, differential pressure sensors and emission monitoring through OBD (On-Board Diagnostics) in certain power ranges. For the mobile genset sector, this framework has entailed a comprehensive redesign of engines, combustion systems and control architectures, with a significant increase in technical complexity and production and maintenance costs.

On the anniversary of the Sustainable Development Goals, it is worth remembering that Europe’s energy transition requires massive electrification and deployment of renewables, but also resilience against intermittency and growing grid stress.

In parallel with the implementation of Stage V, the European Commission and sectoral bodies have opened the debate on a future Stage VI. This new phase is not conceived as a one-off adjustment but as the natural evolution of a regulatory framework aimed at supporting the decarbonisation of the European economy.

The outlook for Stage VI points to several areas of development:

  • Application differentiation. A specific regulatory framework is being considered for emergency gensets (limited use, up to 200 hours per year) as opposed to continuous-use units.
  • Real-world operating conditions. The introduction of tests reflecting in-field engine performance is under discussion, similar to RDE testing in the automotive sector.
  • Compatibility with alternative fuels. Stage VI is expected to acknowledge the growing availability of advanced biofuels and the development of hydrogen applications, incorporating these vectors into compliance schemes.

Thus, the transition from Stage V to Stage VI will not only tighten emission limits but also redefine classification and approval procedures, forcing manufacturers and users to anticipate R&D investments and plan the technological transition of their fleets. This increasingly demanding framework should not be seen merely as a regulatory challenge, but as the catalyst for a broader transformation: the technological evolution of the sector towards a low-emission model. At this stage, the industry’s response goes beyond optimising after-treatment technologies and is directed towards effectively reducing the carbon footprint through renewable fuels, the development of hydrogen-based solutions, and the integration of ecodesign principles in the design and manufacture of equipment.

Aerial landscape of a river surrounded by forests next to a Stage V generator set from Genesal Energy

Sector Decarbonisation: Alternative Fuels, Hydrogen and Ecodesign

Decarbonisation of the sector must therefore be based on three main pillars: the gradual substitution of fossil diesel with renewable fuels, the development of hydrogen-based solutions, and the application of circular economy principles in design and manufacturing. Together, these provide a technological framework that enables emission reductions without compromising start-up reliability, ensuring supply availability in critical environments while anticipating future European regulatory demands.

Among the available solutions, advanced biofuels—particularly hydrotreated vegetable oil (HVO)—represent the most mature alternative for reducing the carbon footprint of both existing fleets and new units. HVO is a synthetic paraffinic fuel, compliant with EN 15940, that can be used in most modern diesel engines without technical modifications. It allows lifecycle CO₂ emission reductions of up to 90%, due to its biogenic origin, and offers additional advantages: it contains no sulphur or aromatics, provides cleaner combustion, delivers 10–18% lower emissions of particulates and NOx in tests, and has remarkable storage stability of up to ten years. From an operational standpoint, it integrates seamlessly into logistics without compromising start-up reliability in critical applications, making it the most immediate lever to advance decarbonisation.

The industry is working on the incorporation of renewable fuels, hydrogen-based solutions and ecodesign principles, so that gensets can maintain their strategic role while effectively reducing their environmental footprint.

Gas engines and dual-fuel applications offer an intermediate option in terms of reducing local emissions and diversifying energy sources. Their deployment, however, depends on the availability of supply infrastructure, which limits their use in applications where security of supply is critical. Even so, developments that enable operation with gas–diesel blends, or with hydrogen additions, open up new transitional pathways to cleaner solutions.

Looking further ahead, green hydrogen is emerging as the reference energy vector for the full decarbonisation of the sector. Pilot projects of gensets running entirely on hydrogen, as well as dual-fuel applications combining diesel and hydrogen, are already being validated by several European manufacturers. Although technical feasibility has been demonstrated, significant challenges remain in terms of production costs, engine durability, energy density and, above all, safe storage and distribution of the gas. In the medium term, hydrogen is considered a realistic solution in environments where it can be produced on-site by electrolysers coupled to renewable sources, as is already happening in certain industrial projects and strategic data centres.

Macro detail of a plant spiral

Finally, ecodesign and the circular economy complete this strategy. More than 70% of a genset’s mass is currently recyclable thanks to the predominance of metals such as steel, copper and aluminium, and with improvements in design and manufacturing processes this figure can exceed 90%. Added to this is the long durability of these units: with proper maintenance, their service life can easily surpass three decades, allowing the impact of manufacturing to be amortised over a wide time horizon. In parallel, certifications such as ISO 14006 incorporate environmental criteria into the design phase, ensuring that products are conceived with a circular approach. Genesal Energy, the first company in the sector to obtain this certification, exemplifies how sustainability can be integrated into technological development strategies and deliver competitive advantages in markets with increasingly stringent environmental requirements.

When environmental performance is analysed from a lifecycle perspective, emergency gensets appear far more sustainable than often assumed. Their short operating times naturally limit cumulative emissions; the adoption of biofuels such as HVO drastically cuts their carbon footprint; and ecodesign maximises their circularity and efficiency. With these improvements, gensets reinforce their alignment with the EU’s circular economy objectives and consolidate an increasingly favourable environmental profile.

Conclusion

On the anniversary of the Sustainable Development Goals, it is worth remembering that Europe’s energy transition requires massive electrification and deployment of renewables, but also resilience against intermittency and growing grid stress. In this balance, gensets are irreplaceable: their limited operating time restricts environmental impact, while their role in ensuring the continuity of critical services is decisive.

Looking further ahead, green hydrogen is emerging as the reference energy vector for the full decarbonisation of the sector.

The Stage V framework has already marked a milestone in emission reduction, and the forthcoming Stage VI will pave the way for the integration of renewable fuels and hydrogen-based solutions, complemented by advances in biofuels such as HVO and in ecodesign.