Do you own a small factory? Any sudden power interruptions would bring you massive loss of production, unnecessarily delayed orders, and hundreds of unhappy customers. That’s why factory owners prefer installing a 100kW Diesel Generator for backup power.
But do you think the 100KW diesel generator is big enough to easily power your small factory? The answer totally depends on how much load you want to power up. What are the startup power requirements and your future expansion plans?
This guide covers everything about power calculations, fuel consumption, cost, and expert sizing tips to help you decide the right power generator size for your factory.
What Is a 100kW Diesel Generator?
A 100kW diesel generator provides 100,000 watts of electricity. In electrical terms, it is equal to 125 kilowatt ampere at the standard 0.8 power factor.
Make sure you know the basic difference between standby and prime power ratings.
- Standby-Stromversorgung: Standby power refers to the maximum power available for emergency blackouts.
- Prime Power: If you want to power up your house for continuous usage, it is known as prime power.
Usually, the factories run for almost 8 Zu 10 hours a day. So, keep an eye on the prime rating. The 100kW standby generator is the right choice if you need 90 kW continuous prime power.
How Much Power Does a Small Factory Need?
A small factory is a broad term. To know whether the 100kW diesel generator is the right fit. Let’s see what equipment you want to power up.
Typical Power Consumption by Industry
- Textile Workshop: Needs power for low load sewing machines. Also, they need power for heavy AC for climate control.
- Packaging Unit: Conveyor belts and heat sealers usually work on moderate loads.
- Small Manufacturing (CNC): CNC machines are sensitive. A single voltage drop will lead to unstable power.
- Welding Shop: Welding machines have maximum inrush currents that can easily trip any small generator.
Common Equipment Power Ratings
Use this reference table for industrial machinery.
| Equipment Type | Approx. Running Watts (kW) | Starting Watts (Surge) |
| Air Compressor (10HP) | 7.5 kW | 22 kW |
| Industrial Motor (20HP) | 15 kW | 45 kW |
| CNC Lathe | 10 – 20 kW | 15 – 25 kW |
| Welding Machine | 8 – 15 kW | High Surge |
| Central AC (5 Ton) | 6 kW | 15 kW |
| Lighting (LED High Bay) | 0.15 kW each | 0.15 kW |
Can a 100kW Diesel Generator Handle the Load?
To calculate the total running load and your peak starting load for the generator, make sure to calculate the power using this formula:
The 80% Rule
Do not run the diesel generator at 100% capacity for long time intervals. It impacts the device’s lifespan and fuel efficiency.
- Safe Continuous Load: 80% of 100kW = 80kW.
Calculation Example
Suppose your small factory has:
- 2x Air Compressors (15kW total)
- 1x CNC Machine (15kW)
- Lighting & Office (10kW)
- Various small motors (20kW)
- Total Running Load: 60kW
Verdict: Ja, for this scenario, the 100kW diesel generator is a perfect choice. It can easily handle 60kW loads. Letztlich, the 20kW headroom is available for motor startups and future expansion loads.
Fuel Consumption of a 100kW Diesel Generator
Remember, fuel cost in today’s era is a major operating expense. A modern 100kW diesel generator is efficient. Still, fuel consumption depends heavily on the load quantity.
Estimated Fuel Consumption:
| Load Percentage | Fuel Consumption (Liters/Hour) |
| 50% Load (50kW) | ~14 – 16 Liters |
| 75% Load (75kW) | ~20 – 23 Liters |
| 100% Load (100kW) | ~26 – 30 Liters |
Note: This is merely a rough estimate. Make sure to cross check your manufacturer’s 100kW diesel generator fuel consumption chart for specific ratings.
Advantages of Using a 100kW Diesel Generator
- Industrial Durability: Unlike portable gas Generatoren, the 100kW diesel generator works efficiently using 4 Zu 6 cylinders and a heavy duty engine that can easily handle thousands of runtime hours.
- Handles High Inrush Current: Its electrical motors need 3X more power to start. If a 100kW unit has a huge magnetic mass inside the alternator, it will effectively handle the spikes.
- Cost-Effective: The diesel fuel is energy-dense. It provides more kW per dollar of energy than gasoline or propane.
- Resale Value: Factory owners who maintain their diesel generators properly get the best value for their power backup plants.
When a 100kW Generator May NOT Be Enough
Now the question is, how would you decide whether a 100kWh diesel generator is not enough? If:
- You have large motors starting simultaneously: You want to turn on 320 HP motors at once; the power surge will automatically exceed 100kW.
- Your factory is expanding: If you are planning to add another production line in the upcoming year. Buying a 100kW unit right now is a waste. It’s better to go for a generator that can handle 150kW of power.
- Sensitive Electronics: Do you have a precision lab or a data center? Make sure to go for an oversized alternator to avoid voltage distortion tithe.
Price of a 100kW Diesel Generator
The price for a 100kW diesel generator varies depending on:
- Brand of Engine: (e.g., Cummins, Perkins, or heavy-duty Chinese brands like Weichai/Yuchai).
- Enclosure Type: Sound proof generators are more expensive than open type. But for urban factories, they help easily tackle the noise regulation problems.
- Controller Features: Auto start features (ATS) and remote monitoring add some extra expenses to the overall generator cost.
Contact HuaQuan Power for the latest pricing update on our 100kW silent diesel series.
Expert Tips Before Buying
- Calculate Peak Load, Not Just Average: Use a clamp meter. Put it on your main breaker panel during a busy day to see the real amp draw.
- Check Phase Balance: Allgemein, factories use 3-phase power. It helps you maintain the power balance across 3 phases to avoid unexpected generator damage.
- Plan for Maintenance: A 100kW diesel generator needs oil changing every 250 Std. (about 1 and a half weeks).
FAQs
How much fuel does a 100kW diesel generator consume per hour?
At 75% load, the maximum available for a factory, a 100kW diesel generator consumes almost 20 Zu 23 liters of diesel per hour.
Can I run my 100kW diesel generator continuously?
Ja. If you own a prime rated unit, you can run it 24/7 unless you stop it for scheduled maintenance such as an oil change.
What size factory gets 100K W power generator support?
These generators easily support small manufacturing units that run up to 80kW. You can handle 2 Zu 3 heavy machines like CNC’s or pressers, air compressors and standard lighting/HVAC on this support.
Is 100kW power enough for industrial machines?
Usually, for small to medium industrial machines, it is enough. However, if your motors are larger than 30 HP and start on Direct-On-Line (DOL), make sure to plant a larger generator to handle the startup load.
Abschluss
The 100kW diesel generator is big enough to easily power a small factory. If your load running time falls between 60 and 80kW and you know how to manage startup loads, it is enough. These generators provide reliable backup power for industrial equipment and effectively operate at 70 Zu 80% of their capacity.
However, if you expand your factory genes and they exceed 85kW power. Choosing a larger generator might be a smarter move. Make sure to calculate your total load time and future expansion requirements before making the final decision. Contact HuaQuan Power experts today for a free load calculation. Get a quote about our 100kW industrial diesel generator here.
