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.

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.

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.

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.

Decarbonisation in industry is not just about technology: it’s about acknowledging operational complexity and the need to combine multiple solutions. Genesal Energy knows this well. That’s why we chose to take action.

Our renovation of units B27 and B28 at the Bergondo industrial estate (A Coruña) is a real example of how to integrate concrete, measured, and coordinated efforts to move towards a more sustainable industry.

Producing renewable energy is not enough, you also need to manage it properly.

In recent years, we’ve taken an active role in the energy transition, convinced that decarbonising our processes is not a choice but a responsibility. However, we are under no illusion: the path is not easy. Challenges are high energy consumption, demanding technical processes, and above all, the need to ensure uninterrupted operational continuity. We understand there is no single solution or magic formula. Every industry is different, and every step matters.

In our case, the first step was analysis. We studied our energy consumption, losses, thermal demand, and the renewable potential of our facilities in depth. Based on that data, we designed an intervention around four pillars:

• Integration of renewable energy
• Smart energy management
• Recovery of energy flows
• Overall efficiency improvement

For renewable generation, we chose to integrate the solution into the architecture of our buildings. We installed 111 sq metres of photovoltaic glass with a capacity of 13.1 kWp directly into the façades, allowing us to generate clean energy while also improving thermal insulation. This was complemented by a 252 m² photovoltaic roof (57.3 kWp) on unit B27. Thanks to these installations, we now cover 100% of the energy consumption of both units during peak solar hours.
But producing renewable energy is not enough, you also need to manage it properly. That’s why we incorporated the OGGY, an advanced energy storage and management system that monitors usage in real time and automatically determines the most efficient use of the available energy. This system helped us reduce consumption by 27% in just one year.

There is no single solution or magic formula. Every industry is different, and every step matters.

We went one step further: we began recovering the energy generated during genset testing (FATs). Thanks to its integration with OGGY, that energy is fed back into the system, further reducing our dependence on the electricity grid.

The results came quickly: in the first year, we avoided more than 23 tonnes of CO₂ equivalent emissions. Our facilities also improved their energy certification, moving from a rating of “E” to “B”. An improvement that reflects not just efficiency, but a genuine commitment to sustainability.

This project has shown us that industrial decarbonisation is not achieved through isolated grand gestures, but through concrete, measurable, and coordinated actions. It requires vision, strategy, and the ability to adapt solutions to the specific needs of each operation. And above all, it requires commitment.
Genesal Energy is clear on this: we’ll keep moving forward.

Author: Antía Míguez Fariña, Sustainability Coordinator, Genesal Energy

Generator sets are essential to ensure uninterrupted power supply in remote locations, critical facilities, or areas with an unstable grid. However, when exposed to extreme conditions—scorching heat, freezing cold or high altitudes—specific solutions must be applied to guarantee optimal performance and extend equipment lifespan.

Challenges of Operating Generators in Extreme Conditions

Environmental factors can directly impact a generator’s performance, reliability and durability. Extreme temperatures, humidity, dust, and even air density at high altitudes present technical challenges that require proper equipment preparation.
The main challenges include:

• Difficult cold-weather starting.
• Overheating in arid climates.
• Loss of rated power at high altitudes.
• Increased wear on mechanical and electronic components.
• Need for reinforced cooling systems.

Overcoming these challenges demands adaptive engineering, durable materials, and an optimised configuration tailored to each environment.

Adaptations for Cold Climates: Generators in Arctic Zones

In polar or mountainous regions where temperatures drop well below zero, a standard generator may struggle to operate reliably. To ensure performance in these environments, several measures are implemented:

• Engine and fuel preheating systems, enabling starting in temperatures as low as -30 °C.
• Thermally insulated enclosures to shield internal components from extreme cold.
• Low-viscosity lubricants and fuels suitable for Arctic climates.
• Battery and alternator heaters.

These adaptations ensure that the generator can effectively meet critical energy needs, for instance in scientific bases, telecommunications infrastructure, or emergency systems in sub-Arctic areas.

Operation in High Temperatures: Solutions for Desert Environments

In desert climates—where temperatures can exceed 50 °C and dust levels are high—several parts of the generator must be reinforced:

• Oversized cooling systems, with additional fans or high-efficiency radiators to prevent overheating.
• Specialised air and dust filters to block abrasive particles from entering the engine.
• Protection of electronic components from direct solar radiation.
• UV-resistant paints and coatings.

The goal in these environments is to keep engine temperature within safe operating ranges and prevent dirt accumulation that could impair combustion or damage components.

The Importance of Cooling Systems in Extreme Conditions

Cooling systems are critical for generator sets exposed to extreme temperatures. Whether in high heat or freezing cold, efficient thermal management is essential to avoid mechanical failure, efficiency loss or irreversible engine damage.

Common cooling solutions include:

• Liquid cooling with special antifreeze for cold environments.
• Tropical-grade radiators or large-capacity heat exchangers for hot climates.
• Redundant ventilation or forced-air cooling systems.

Continuous monitoring of temperature and cooling pressure helps extend the generator’s lifespan and ensures optimal performance.

How Altitude and Air Density Affect Generator Performance

As altitude increases, air density decreases, which negatively affects combustion and, consequently, the power output of the generator. This results in:

• Reduction in rated power (up to 10% for every 1000 metres above sea level, depending on the model).
• Increased load on the intake and exhaust systems.
• Requirement for specific calibrations to adjust the air-fuel mix.

Therefore, for applications in mountainous or high plateau areas, the generator must be calibrated and fitted with systems to offset these conditions, such as tuned turbochargers or adapted electronic configurations.

Protection and Maintenance to Prolong Equipment Life

Generators designed for extreme environments require a stricter maintenance plan and additional protective measures:

• More frequent inspection of filters, oil and coolant.
• Regular checks of the electrical system and thermal insulation.
• Preventive cleaning to counteract sand, ice or salinity depending on the environment.
• Use of anti-corrosion coatings and components resistant to thermal shock.

These measures not only help avoid breakdowns, but also ensure reliable performance in the harshest conditions.

Use Cases and Applications in Critical Sectors

Generators engineered for extreme conditions are vital in sectors where power failure is not an option:

• Defence and security: military operations in desert or polar zones.
• Oil and gas: platforms or fields in remote or hostile regions.
• Emergency and rescue: humanitarian camps or temporary installations.
• Scientific exploration: Arctic research stations or desert locations like the Sahara or Atacama.
• High-altitude mining: projects in the Andes or the Himalayas.

In all these cases, generator design must meet specific power requirements with long-term reliability, performance and resilience.

Technological Trends to Enhance Generator Resilience

Technological advancements continue to improve generator resistance to extreme environments:

• Smart sensors and IoT systems for remote monitoring of operating conditions.
• Self-diagnosis systems to detect faults before they occur.
• New insulating and lightweight materials that better withstand thermal and mechanical stress.
• Compact, modular designs for easier transport and installation in remote locations.

In addition, alternative fuels such as HVO or natural gas are being integrated, offering more stable performance under certain environmental conditions.

Conclusion

Preparing a generator set for extreme conditions is not optional—it is essential to ensure operational efficiency and performance. From the Arctic to the desert, each environment demands a tailored technical approach adapted to its temperature, altitude and energy requirements. Investing in robust, well-designed and properly maintained equipment is the best way to guarantee long-term reliability.

“Backup power isn’t a luxury – it’s a need. This blackout has shown us something essential: the importance of being prepared.”-Ángeles Santos, Director of HR and Institutional Relations at Genesal Energy

At 12:33pm CEST on the 28th of April, the Iberian Peninsula experienced an unprecedented event: a massive blackout that affected more than 55 million people. For hours, entire regions were left in the dark, with services interrupted and widespread uncertainty that exposed how vulnerable the power grid is to unexpected failures.

The consequences were immediate, impacting every sector of society: supermarkets closed, ATMs stopped working, traffic lights went out, telecommunications were disrupted, transport collapsed, petrol stations were out of service, industry ground to a halt – and the list goes on. The incident clearly demonstrated our deep dependence on a continuous and reliable power supply to keep daily life running.

And it’s not just about day-to-day activity; some sectors require an uninterrupted power supply under all circumstances. Hospitals, for example, rely on electricity to operate life-saving equipment like cardiac monitors and ventilators, and to carry out emergency procedures. Thanks to emergency generators, many of these facilities were able to continue operating normally.

Beyond the immediate impact, the blackout served as a stark reminder of the need for effective backup power solutions such as generator sets – and the need to guarantee their availability through proper maintenance. Being prepared isn’t just about having the equipment installed but ensuring it will respond when it’s needed most.

The Importance of Grid Security

The Iberian power system is made up of various energy generation plants (wind farms, solar parks, hydroelectric stations, combined cycle plants, etc.), which are interconnected by high-voltage transmission lines. These lines in turn connect to transformer substations, which lower the voltage from high to medium or low levels, before distributing electricity to points of use via medium and low-voltage networks.

Generator maintenance is essential in any sector that depends on these systems.

So, every time we switch on a light or plug in an appliance, we’re setting off a complex process that is constantly monitored to ensure energy generation matches demand – maintaining a fine balance between what’s produced and what’s consumed. However, the system is vulnerable: any failure can cause a power outage in a matter of seconds, as the recent blackout has shown.

That’s why many sectors – particularly those considered critical – must be equipped with backup power systems to guarantee supply continuity in the event of a grid failure:

• In healthcare, a power outage can be life-threatening, as many patients rely on machines that must remain continuously powered. Emergency procedures cannot be delayed due to a lack of electricity.
• In sectors such as data-centres and telecommunications, uninterrupted power is essential to maintain operations, prevent data loss and ensure emergency communication.
• In industry, stopping production processes can cause damage to equipment, faults and major financial losses due to delays and downtime.

Ensuring an uninterrupted power supply – and with it, the safety of people and the resilience of industry – is not only a necessity, but a moral responsibility. In this context, emergency generator sets play a vital role as an alternative energy source.

How Do You Make Sure a Generator Responds When Needed?

It all starts with a proper installation and a configuration that allows for automatic response. A generator set includes key components like the engine, alternator and control panel. But its true value lies in its ability to activate without human intervention, thanks to the automatic transfer switch (ATS) – a device that detects a power cut, starts up the generator, and transfers the electrical load in a matter of seconds. This immediate reaction keeps power flowing during even the most critical moments.

But for this seamless response to work, one element is just as important as the system design itself: maintenance.

The Value of Maintenance: Ready for the Unexpected

Generator maintenance is essential in any sector that depends on these systems. It helps detect wear and tear, prevent unexpected breakdowns, and correct minor faults before they escalate and compromise system performance.

These tasks cover both the mechanical and electrical components and are carried out with the generator both stopped and running. Checks include:

• Electrical, hydraulic and pneumatic connections
• Fuel system (pump, filters)
• Lubrication system (oil level and replacement, filters)
• Cooling system (coolant level and condition, radiator cleaning)
• Battery condition (charge level, electrolyte levels, terminal cleaning)
• Exhaust system (silencers and emissions)

Adjustments are made depending on the overall state of the equipment. Load tests are also carried out regularly to ensure all operating parameters remain within optimal limits, and alarm and safety systems are verified to guarantee an effective response if triggered.

Thanks to this process, critical infrastructure – including hospitals, data centres and industrial plants – can continue to operate in emergencies. Lives are saved, information is protected, essential services remain functional, and the supply chain stays active. In short, maintenance turns generators into a true guarantee of continuity.

More Than Just a Response: The Broader Benefits of Preventive Maintenance

In addition to ensuring an immediate response during a power failure, preventive maintenance brings a host of long-term benefits that directly impact safety, efficiency and operational profitability:

• Safety. Proper maintenance prevents internal failures that could lead to accidents such as fires or explosions, protecting both people and property.
• Improved performance and lifespan. Regular checks and adjustments reduce premature wear and tear, ensuring the genset runs in optimal condition.
• Lower costs. Early fault detection helps avoid costly repairs. A well-maintained generator also consumes fewer resources (fuel, coolant, etc.).
• Regulatory compliance. In many sectors, having generators is not only essential, but so is complying with specific maintenance regulations. Avoiding fines is also part of good management.
• Business reputation. A preventable failure due to poor maintenance can severely damage a company’s image – especially if it puts customer service at risk.

The Genesal Energy Experience

Genesal Energy knows that the key to ensuring energy continuity lies in foresight and maintenance. A generator is only useful if it’s ready to run when the time comes. That’s why, in addition to designing and manufacturing tailor-made power solutions, we offer a comprehensive Technical Support Service (SAT) to accompany each customer throughout the entire lifecycle of their equipment.

Through it, we define, design and implement maintenance plans tailored to the specific needs of each installation, with 24/7 expert support. We also handle generator installation and commissioning, ensuring everything is ready to respond to any contingency.

One clear example of this capability was our response to the blackout on the 28th of April. Given the scale of the event, we activated a crisis unit to resolve as many incidents as possible, prioritising the most urgent. Thanks to the commitment and professionalism of our technicians, we managed to restore power to numerous critical locations, delivering energy where it was needed most.