1,000 kVA Standby Generator for Global Food Manufacturing Facility
Project Overview
This project was delivered for a globally recognised food manufacturing plant operating within a demanding 24/7 production environment, where any loss of power could have a significant impact on output, safety, and business continuity. During a planned switchgear refurbishment, it was identified that the site had no standby or contingency power provision, leaving the facility vulnerable to mains power failures.
The project followed a trusted supply chain, with the end user appointing an approved electrical contractor, who engaged YESSS Electrical, with Lance Power selected as the generator supplier and power solutions specialist.
The Challenge
The primary requirement was to install a high-capacity standby diesel generator capable of integrating seamlessly with the new switchgear system, while maintaining uninterrupted site operations. The facility operates continuously, with no opportunity for shutdown, and experiences constant vehicle movements and deliveries throughout the day. Cable routes also needed to be installed beneath an active roadway, adding further complexity to the project.
To minimise disruption, extensive planning and coordination were required, with multiple stakeholder meetings held to ensure all works could be delivered with the least possible impact on production and site logistics.
The Solution
Lance Power supplied a 1,000 kVA Baudouin diesel generator, designed to provide reliable standby power and long-term resilience. The generator was configured with a Leroy-Somer alternator, Deep Sea Electronics controller, and ABB circuit breakers, ensuring compatibility with the refurbished switchgear and robust electrical protection.
The system included a range of bespoke upgrades to suit the site’s operational needs, including dual water jacket heaters, a 24-hour integral fuel tank, remote monitoring for real-time performance visibility, and a custom colour finish to allow the generator to blend into its surroundings. To maximise reliability and asset lifespan, the installation was supported by a 7-year service and maintenance contract, incorporating three services per year and annual load bank testing.
Installation & Commissioning
Due to the site’s 24/7 operation, installation activities were carefully phased and largely carried out over weekends. Cable installations beneath the roadway were coordinated around ongoing deliveries, ensuring safe access at all times. Close collaboration between Lance Power, the electrical contractor, and YESSS Electrical ensured smooth execution throughout.
Commissioning was completed through a series of planned visits, including full system testing, blackout simulation tests, and operator training for on-site staff. The process was delivered seamlessly, with no impact on live operations.
The Result
The facility now benefits from a robust standby power contingency plan, protecting production processes and safeguarding business continuity in the event of a mains failure. The solution provides rapid response during power outages, improved operational resilience, and long-term peace of mind.
Feedback from the customer was extremely positive, with the Head of Operations highlighting the smooth delivery and minimal disruption to site operations. The appointed electrical contractor also provided excellent feedback, praising the collaborative approach and coordination across all parties involved.
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