Home / Custom hybrid builds
Custom engineering
Built for your load, not for a brochure.
Where a catalogue unit does not fit, we design and build hybrid generating systems from components — engine, battery, inverter and controls specified around what the site actually needs.
When a standard unit will not do
- An unusual load shape — very peaky, very flat, or with a starting current that dictates something a standard set cannot manage sensibly
- Space or access constraints — it has to fit through a gate, into a plant room, or onto a specific footprint
- Redeployment — built into a container or on a trailer so it moves between sites without being rebuilt
- Integration with existing generation, switchgear or a building management system
- Fuel that is not diesel — LPG or natural gas, where the standard hybrid market is much thinner
- Noise or emissions limits that a standard enclosure will not meet
What we build
| Element | Specified around |
|---|---|
| Generating set | Rating chosen for charging plus peak load, not for peak alone — usually a smaller engine than a non-hybrid design would need. |
| Battery | Capacity from your base load and required silent running period. Chemistry and enclosure from the environment it will live in. |
| Inverter charger | Sized for peak output and charge rate. Single or three phase, with the transfer arrangement to match. |
| Solar | Where the site has room. Container roof, ground frame or existing building. |
| Controls | Start and stop logic, state of charge thresholds, load shedding, quiet hours, and remote monitoring. |
| Enclosure | Container, cabinet, trailer or plant room. Acoustic treatment, bunding, ventilation and security as required. |
The part that gets underestimated
Assembling the hardware is straightforward. The control strategy is where a hybrid system is won or lost.
Badly set up, a hybrid will start its engine too often, run it too briefly, and end up worse than the diesel it replaced — more starts, more wear, and no fuel saved. The thresholds have to suit the load shape, and they usually need adjusting once real data comes back from the site.
Which is why we commission properly
We set the system up, then look at how it actually behaves over the first weeks and tune the thresholds against real data. A hybrid handed over on default settings is only part-finished.
Remote monitoring
Every custom build we do includes monitoring, because a hybrid system produces data worth having:
- Engine run hours and starts, so servicing follows use rather than the calendar
- Fuel level, so refuelling is planned rather than urgent
- Battery state of charge and health over time
- Load profile, which usually reveals savings nobody had thought about
- Alarms, before a problem becomes an outage
How a project runs
- Requirements and site survey. Load, environment, constraints, access.
- Metering, where the load is not already well understood.
- Concept design and budget, so you can decide before detailed work starts.
- Detailed design — schematics, general arrangement, control philosophy.
- Build and works testing before anything goes to site.
- Installation, commissioning under load, and handover with documentation.
- Tuning after the first weeks of real operation.
Got a requirement nothing off the shelf fits?
Tell us the constraints. We will tell you whether it can be built and what it would take.
Discuss a build