How to Choose the Right Generator for Your Company’s Industrial Power Needs

Choosing the right industrial generator set is a critical decision for any company that depends on continuous production and safe, stable processes. Whether we are talking about factories, logistics warehouses, processing centers, or construction sites, an undersized or improperly selected generator can lead to unplanned downtime, additional costs, and major operational risks.

When it comes to generator sets, it is equally important to work with a reliable partner. Best Tools is the official Rehlko distributor in Romania, providing professional industrial solutions tailored to the real needs of each client.

Understand your company’s load profile

The first step in choosing a generator set for industrial use is a detailed analysis of your load profile:

• Installed power (total rating of all connected equipment)
• Actual absorbed power during normal operation
• Load peaks and when they occur
• Constant vs. variable consumption (shifts, seasonal production lines, etc.)

It is essential not to size the generator only according to installed power, but according to actual required power and the simultaneity of the loads. In many cases, some consumers can be started sequentially or prioritized.

Type of application: backup, prime power, or mixed

How you plan to use the generator has a direct impact on the type of equipment you need.

Generator for backup (standby)

Used when there is a public grid, but you need protection against outages.
Recommended for:

• Warehouses and logistics halls
• Office buildings
• Industrial areas with unstable grid supply

In this case, the generator is configured in standby mode and starts automatically via an ATS (Automatic Transfer Switch) when the grid fails.

Generator as prime or continuous power source

Used in areas without grid access or in applications where consumption is constant and high:

• Production units in remote areas
• Large construction sites
• Pumping stations and other critical technological installations

Here, you need a generator sized for long-term operation, with a prime or continuous rating, with strong focus on fuel efficiency and operating costs.

Analyze the type of load: motors, sensitive equipment, or mixed

Not all electrical loads behave the same way. The type of consumer has a direct influence on generator selection:

• Electric motors (pumps, compressors, fans, production lines):
  • have a high inrush current (3–7 times the nominal current)
  • may require temporary oversizing of the generator or the use of soft starters / variable frequency drives
• Sensitive electronic equipment (servers, automation equipment, PLCs):
  • requires stable voltage and low THD (Total Harmonic Distortion)
  • may need a combination of generator + UPS
• Mixed loads (motors + electronic equipment):
  • require careful analysis of the power factor, starting current, and starting sequence of the loads
  • in many cases, it is advisable to split loads into priorities: critical and non-critical

Correct sizing: bigger is not always better

A common myth is that “it is safer to choose a generator much larger than needed”. In reality:

• A generator that is too small → risk of overload, voltage drops, shutdowns, and premature wear
• A generator that is too large → unnecessary fuel consumption, operation at low load, deposits, and low efficiency

That is why you must consider:

• Apparent power (kVA) and active power (kW)
• Power factor of the load (usually 0.8 in industrial applications)
• Starting coefficient for motors (especially if several start at the same time)
• Potential future extensions of production capacity

A correctly sized Rehlko industrial generator set, configured by the Best Tools team, ensures stable operation and optimized costs.

Single-phase or three-phase, voltage, and compatibility with your existing installation

In industrial environments, in most cases you will need a three-phase generator, at 400 V. However, you should assess:

• The ratio between single-phase and three-phase loads
• Load distribution across phases to avoid imbalance
• Compatibility with the existing distribution board and possible additional investments in panels and protections

You also need to clearly define the available short-circuit power, to ensure that protection devices (fuses, automatic breakers) work correctly.

Installation conditions: indoor, outdoor, noise, and environment

The environment in which the generator will operate has a strong influence on its technical configuration:

• Outdoor installation
  • requires a soundproof, weatherproof canopy with appropriate IP rating
  • resistance to extreme temperatures, rain, and dust
• Indoor installation (cogeneration plant or technical room)
  • needs ventilation and exhaust systems properly calculated
  • careful analysis of airflow and ambient temperature
• Areas with noise restrictions (urban zones, proximity to offices or residential areas)
  • require low-noise, silent generators
  • installation in special soundproof containers may be necessary

Technology and brand: reliability is non-negotiable

In industrial environments, reliability is critical. It’s not only about the purchase price, but also about:

• the quality of the engine and alternator
• voltage and frequency stability
• fuel consumption at different load levels
• ease of maintenance and availability of spare parts

Rehlko is a recognized brand in the field of reliable, efficient industrial generators, and Best Tools, as the official Rehlko distributor in Romania, offers:

• access to the full range of Rehlko industrial generator sets
• custom configurations for each specific application
• technical consulting, commissioning, and authorized service

Reference table: how to choose based on application

This table is for guidance only. Final sizing and selection must be based on a detailed technical analysis performed by specialists.

Total Cost of Ownership (TCO): don’t look only at the price tag

An industrial generator is not just its purchase price. For a realistic assessment, you must consider:

• Fuel consumption (according to the typical load profile)
• Periodic maintenance (oil changes, filters, inspections)
• Costs for spare parts and service interventions
• Estimated service life of the equipment
• Possible future upgrades or extensions (synchronization with other generators, integration with solar PV, etc.)

A well-selected and properly operated Rehlko generator set can significantly reduce total cost of ownership and increase operational safety.

The role of a technical partner: why work with Best Tools

Choosing the right generator set is not just about a catalog and a price list. That’s why working with a specialized partner is essential.

Best Tools, as official Rehlko distributor in Romania, offers:

• On-site power audits and load analysis
• Accurate sizing of the generator set according to the application
• Custom configuration proposals (backup, prime, synchronized systems)
• Commissioning, staff training, and full documentation
• Service, maintenance, and spare parts over the long term

Conclusion: the right generator means safety and efficiency

For an industrial company, choosing a generator set that matches the real power demand means:

• safe operation
• protection of production and equipment
• optimized long-term costs
• flexibility in the face of grid issues or future expansion plans

With Rehlko solutions and Best Tools expertise, you can turn power supply from a risk factor into a competitive advantage.