A food processing factory in central Italy faced a problem that affected its entire operation. The factory produced packaged pasta and sauces for supermarkets across Europe. Production ran 24 hours a day, five days a week. The facility relied on continuous power for refrigeration, mixing, cooking, and packaging.
But the local power grid was unreliable. Blackouts occurred 4-6 times per year, each lasting 2-8 hours. More frequent were brownouts—drops in voltage that damaged sensitive equipment. The factory lost production during each outage. Refrigerated ingredients spoiled. The factory had to discard batches of product. The owner estimated each major outage cost €8,000-€10,000 in lost production and spoiled materials.
The factory owner understood exactly what his backup power solution required. It must:
- Activate automatically upon grid failure.
- Maintain silent operation due to the nearby residential zone.
- Deliver sufficient power to cover the factory’s 120kW peak usage.
This article tells his real story. You will see the challenges he faced, how he chose YG’s silent generator set, and what results he achieved.
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A Busy Food Factory with a Serious Power Problem
The customer operates a food processing factory in central Italy. The facility produces dried pasta, pasta sauces, and ready meals. The factory employs 45 people and runs two 12-hour shifts. The facility includes a refrigeration room, cooking kettles, mixing stations, and packaging lines—all requiring continuous power.
Before buying from YG, the customer used no backup generator. They relied solely on the grid. When outages occurred, production stopped completely. The owner calculated that each outage cost approximately €8,000-€10,000 in lost production, spoiled ingredients, and wasted labor. Over the previous year, the factory experienced five outages totaling 18 hours. The total cost exceeded €40,000.
The owner had three main requirements for a backup generator. First, the unit needed to provide at least 150kW of continuous power to cover the peak load. Second, the unit needed to start automatically within 15 seconds of a grid failure. Third, the unit needed to operate quietly enough for a residential area.
The facility manager started searching for a genset for sale that could meet these requirements.
The Real Cost of Unreliable Power
The factory owner faced six major problems caused by the unreliable grid.
- Production losses. Each outage stopped production completely. Workers stood idle during the outage. The factory lost 2-8 hours of output each time. Over the year, this added up to 18 lost production hours.
- Spoiled ingredients. The refrigeration room stored raw meat, dairy products, and fresh vegetables. An outage longer than 2 hours meant the refrigerator temperature rose above safe levels. The factory had to discard spoiled ingredients. Each outage costs €2,000-€3,000 in spoiled food.
- Wasted product. When an outage occurred during cooking or packaging, the factory had to discard partially processed batches. This wasted ingredients and labor. Each outage costs €1,500-€2,500 in wasted product.
- Equipment damage. Brownouts and power surges damaged control boards on the cooking kettles. The factory replaced three control boards in one year for €1,200 each.
- Delayed shipments. Production delays meant shipments to supermarkets arrived late. The factory had to pay expedited shipping costs. Some customers imposed penalty fees.
- Customer complaints. Supermarkets expected a reliable supply. The late deliveries damaged the factory’s reputation. One supermarket threatened to switch to a competitor.
The owner calculated the total annual cost of power issues at approximately €45,000. He decided to invest in a silent generator set to eliminate these costs.
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Finding a Reliable Silent Generator Set
The facility manager started searching online for a silent generator set. He needed equipment with specific capabilities.
First, the generator needed at least 150kW of continuous power. The factory’s peak load reached 120kW. A 150kW unit would provide a comfortable safety margin.
Second, the generator needed an automatic transfer switch. The unit had to start automatically when the grid failed. It also needed to switch back to grid power when utility power returned.
Third, the generator needed a soundproof enclosure. The factory sat 200 meters from a residential area. Noise regulations limited nighttime noise to 65 decibels at the property boundary.
Fourth, the generator needed to operate reliably in Italy’s climate. Summer temperatures can reach 38°C. The unit needed adequate cooling.
The manager contacted several suppliers. He requested quotes for a 150kW genset for sale. Some suppliers offered generators with long lead times of 60 days. Other suppliers offered lower prices but could not provide soundproof enclosures. Then he found YG Machinery.
YG’s 150kW Silent Generator Set: The Right Fit
YG’s sales engineer asked detailed questions about the factory’s power needs. What equipment runs simultaneously? What is your peak load? Do you need automatic start? What are your noise requirements?
Based on the answers, YG recommended the 150kW silent generator set. The factory owner reviewed the specifications and agreed. Here are the key specifications of the YG 150kW unit:
| Power | 30kw | 100kw | 150kw | 200kw | 300kw | 400kw |
|---|---|---|---|---|---|---|
| Cylinders | 4 cylinder | 6 cylinder | 6 cylinder | 6 cylinder | 6 cylinder | 6 cylinder |
| Voltage | 400/230V | 400/230V | 400/230V | 400/230V | 400/230V | 400/230V |
| Frequency Range | 50HZ | 50HZ | 50HZ | 50HZ | 50HZ | 50HZ |
| Rotating speed | 1500rpm | 1500rpm | 1500rpm | 1500rpm | 1500rpm | 1500rpm |
| Cylinder diameter *stroke (mm) | 100*115 | 105*125 | 105*130 | 126*130 | 126*155 | 135*160 |
| Rated current | 54A | 180A | 270A | 360A | 540A | 720A |
| Phase | Three-phase four-wire | Three-phase four-wire | Three-phase four-wire | Three-phase four-wire | Three-phase four-wire | Three-phase four-wire |
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The 150kW generator set offers several advantages
- Ample power capacity. The 150kW output covers the factory’s 120kW peak load with a 25% safety margin. The six-cylinder engine provides smooth, stable power.
- Automatic transfer switch. The unit includes an ATS that monitors grid power continuously. When the grid fails, the generator starts automatically within 12 seconds. When grid power returns, the unit transfers back and shuts down.
- Soundproof enclosure. The factory installed the generator inside a soundproof enclosure that reduces noise to approximately 65 decibels at 7 meters. The unit meets the local noise regulations.
- Stable frequency and voltage. The generator operates at 1500rpm and delivers 50Hz power. The voltage regulation maintains 400/230V within ±0.5%.
- Weather-resistant construction. The IP54 protection rating makes the unit suitable for outdoor installation. It withstands rain, dust, and temperature variations.
- Comprehensive safety features. The unit includes overvoltage protection, undervoltage protection, overload protection, short circuit protection, high temperature shutdown, low oil pressure shutdown, and emergency stop.
- Fuel efficiency. The six-cylinder engine consumes approximately 28 liters per hour at full load. This provides 8-10 hours of operation on a full fuel tank.
The customer placed the order for one 150kW generator set with ATS and soundproof enclosure.
From Order to Operation: Silent DG Delivery and Installation
Factory production and testing
YG Machinery delivered the silent generator set within 25 working days. At every assembly station, the team adhered to the company’s strict quality checklist. Their testing regimen included engine leak checks, full-load generator trials, noise-level measurements with the acoustic enclosure in place, and a full simulation of the automatic transfer switch.
The unit passed every test. YG sent the customer a video of the generator operating in the factory. The customer approved the shipment.
Shipping to Italy
The generator traveled from YG’s factory to the port by truck. The sea freight took 22 days to reach the Port of Genoa in Italy. Customs clearance took 5 days. YG provided all necessary documentation.
A flatbed truck carried the generator from Genoa to the factory site. The total shipping time from the factory to the site was 35 days.
On-site installation
YG Machinery offered remote installation guidance through a video call, while the customer’s electrician worked through the installation manual step by step. The scope of work included pouring a concrete foundation, positioning the generator on it, and hooking up the fuel supply, exhaust system, and electrical cables to the main distribution panel. The automatic transfer switch was also connected to the grid supply.
The installation took three days. The electrician ran a series of tests. The generator started on the first attempt.
System integration
The ATS is connected to the main electrical panel. The system now monitors grid power continuously. When the grid fails, the ATS signals the generator to start. The generator starts, stabilizes, and transfers power to the factory. The transfer takes approximately 15 seconds.
Operator training
YG provided a comprehensive training manual and video tutorials. The customer trained two maintenance staff members. The training covered daily startup and shutdown procedures, fuel system checks, battery maintenance, oil and filter changes, ATS operation, and basic troubleshooting.
Every staff member received hands-on practice operating the generator. They were trained to carry out weekly test runs, inspect fluid levels, and interpret the control panel readings.
Significant Improvements with Silent Generator Set
The customer tracked key metrics for 60 days after the silent generator set began operation.
- Zero production losses. The factory experienced two grid outages during the 60 days. The generator started both times automatically. Production continued without interruption. The factory lost zero production time.
- Zero spoiled ingredients. The refrigeration remained powered during both outages. The factory discarded no spoiled ingredients. The owner saved approximately €5,000 in avoided spoilage during the two outages.
- Zero wasted product. The cooking and packaging lines continued operating during both outages. The factory completed all batches. The owner saved approximately €3,000 in avoided product waste.
- No equipment damage. The generator provides clean, stable power. No brownouts or surges have occurred since installation. The factory has not replaced any control boards.
- On-time deliveries. Production schedules remained on track. The factory met all delivery deadlines. Supermarkets received shipments on time.
- Quiet operation. The soundproof enclosure keeps noise at 65 decibels at the boundary. The factory has received zero noise complaints from residents.
What the Owner Says About the Silent Generator Set
The factory owner shared his experience after two months with the generator set.
“The YG generator set has eliminated our power problems. We have had two grid outages since installation. The generator started both times automatically. Production never stopped. We did not lose a single batch of product. The unit is quiet. We have had zero noise complaints. The fuel efficiency is good. The maintenance is simple. I am already recommending YG to other factory owners.”
The maintenance supervisor added his perspective.
“The silent generator set is easy to maintain. The control panel is clear. The access points for oil and filters are convenient. The weekly test run takes 15 minutes. The automatic transfer switch works reliably. I have confidence in the system. I know it will work when we need it.”
What’s Next for Genset for Sale
The customer plans to add a second silent generator set to provide backup for future factory expansion. They are also considering a mobile DG set for use at other facilities. The owner has recommended YG to two other food manufacturers in the region. One has already requested a quote for a genset for sale.
YG Machinery continues to provide remote technical support. The YG service team responds to questions via email within a few hours. They have shipped a spare parts kit including filters, belts, and fuses to the customer.
Contact YG Machinery today for your silent generator set needs. Tell us your power requirements and installation location. We will recommend the right model and send you a full price, including shipping to your port. Every unit comes with a warranty and lifetime technical support.
Click the contact button now to request a quote. Ask for our free power outage cost calculator to estimate your potential savings.
