Generators for Industry and Manufacturing

Product Description

In a manufacturing facility, a power outage can mean machinery shutdowns, loss of materials in process and delivery delays. Even after power returns, resuming operations may require inspections, recalibration or a staged restart of equipment. Industrial backup generators support priority processes and limit the consequences of utility power outages.

What needs to be powered in a factory?

The backup solution is configured around the impact of each process stopping. Some facilities need to keep selected production lines running, while others prioritise protecting equipment and shutting down processes safely.

Depending on the operation, priority loads may include:

• Machinery and production lines: processing, assembly, dosing or packaging equipment.
• Auxiliary systems: pumps, compressors, cooling, ventilation and extraction systems.
• Automation and IT infrastructure: controllers, process monitoring systems and production management equipment.
• Product storage systems: refrigeration or equipment maintaining controlled temperatures.
• Safety and emergency response circuits: loads needed to manage an outage safely.

Sizing starts with the processes that actually need to be supported, rather than automatically covering the factory’s entire installed capacity. Setting priorities aligns the investment with the actual consequences of a shutdown.

How is a generator sized for manufacturing?

Steady-state demand is only part of the assessment. Electric motors can draw high starting currents, while connecting major equipment creates load steps that the generator must handle without voltage or frequency variations exceeding the supplied equipment’s tolerances.

The assessment considers active and apparent power, power factor, motor starting requirements and the behaviour of loads such as variable-frequency drives, UPS systems and welding equipment. The load connection sequence and planned expansions also influence the final configuration.

For high power demand or redundancy requirements, the solution can include multiple synchronised generators. Parallel operation allows loads to be shared between units within an architecture designed around the factory’s requirements.

Power transfer and process restart

The generator needs time to start and stabilise its electrical output before taking over the loads. For automation systems and equipment that cannot tolerate this interruption, UPS systems or other dedicated solutions must be integrated appropriately.

Restoring power does not automatically mean production resumes. Some machines require operator confirmation, process condition checks or a specific restart sequence. Automatic transfer controls must account for these requirements to avoid connecting large loads simultaneously and prevent uncontrolled restarts.

Testing and maintenance aligned with factory operations

Load testing and automatic transfer checks allow the system to be assessed before an actual outage occurs. Scheduling these activities with the factory’s technical team helps protect ongoing processes.

Preventive maintenance, fuel checks and refuelling procedures contribute to system availability. Runtime must match the supported load and the operating duration needed to continue production or complete a controlled shutdown.

Best Tools solutions for industry and manufacturing

Best Tools Company provides Rehlko industrial generators and backup power solutions tailored to manufacturing facilities, from consultancy and configuration to delivery and commissioning.

Ongoing support includes preventive maintenance contracts, load testing and service interventions, delivered through its technical team and nationwide network of mobile service units. Rental solutions are also available for temporary requirements or while work is carried out on existing installations.

Contact the Best Tools team to configure a backup power solution tailored to your manufacturing processes.