Keeping the next edition in view
In newspaper production, the pressroom works to a timetable that continues beyond the factory doors. Printing, dispatch and distribution all depend on a carefully organised production window. A mains interruption can put that window under pressure, making standby power an important part of the facility’s continuity planning.
For this established UK newspaper printing business, the requirement was to replace an ageing standby generator while temporary hire equipment was already supporting the site. The selected solution was a Cummins-powered Blackwell C220 HD, rated at 220 kVA ESP. Our parent company, FW Power, coordinated the generator supply, site assessment and installation planning.
A 220 kVA Blackwell generator prepared for standby duty
The C220 HD provided the specified 220 kVA emergency standby capacity for the replacement project. Before delivery planning, the generator successfully completed a full load-bank test and pre-delivery inspection. That preparation was an important step before coordinating transport, lifting and the site connection work.
For buyers comparing a 220 kVA diesel generator, the rating must be read alongside its intended duty. This project specifies emergency standby power, not a claim of 220 kVA continuous operation. A similar printing or manufacturing facility should have its own loads and operating requirements assessed before choosing a set.
The installation challenge was in the cables
Replacing the generator exposed a practical constraint: the existing armoured power cables terminated close to the old machine, with little spare movement. The new Blackwell set had different connection positions. A straightforward swap therefore needed more thought than matching the headline power rating.
The site survey gave the team a clearer picture of the cable layout and the age of the terminations. Rather than relying on moving those fixed cables into a new position, the proposed design introduced a separate connection point between the building’s electrical infrastructure and the replacement generator.
A busbar junction box creates a practical connection point
The connection arrangement centred on a purpose-built junction box containing busbars, positioned near the existing cable entry. The fixed armoured cables would terminate there, with flexible power cables completing the connection to the generator. Cable tray and supporting components were included in the proposed installation scope.
This creates a defined interface between the site and its standby set. The aim was to limit disturbance to the existing armoured cable terminations and make a future generator replacement easier to plan. The project photograph shows the busbar arrangement during installation, with the enclosure open for the photograph.
Planning the transition from hired power
The bespoke junction box had a manufacturing lead time, so the replacement programme included an interim stage. FW Power planned the removal of the old set, positioning of the new Blackwell generator and temporary Powerlock cable connections, followed by a return visit for the permanent connection work.
That sequence was intended to let the customer’s own generator support the standby requirement while the permanent connection equipment was being prepared. It also provided a route towards releasing the hired generator. Transport, lifting access, temporary cables and engineering attendance all had to be considered together.
For a facility working to daily production deadlines, that planning matters. The documented approach set out how temporary connections and the later permanent installation could fit into one coordinated replacement programme.
Cummins power, supported by practical project planning
At the centre of the package is a Cummins diesel engine within the Blackwell generator set. Around it sits the work that makes an industrial standby power project practical: checking the machine before dispatch, understanding the existing electrical connection and organising how the replacement reaches its operating position.
This newspaper printing project illustrates why generator supply and installation planning belong in the same conversation. A well-prepared specification addresses both the power requirement and the physical constraints of the site.
What to check before replacing an industrial standby generator
If your printing facility or manufacturing site is reviewing its backup power, use the existing installation as the starting point. Share the following with the generator team:
- The loads that need standby power, including motor starting requirements and the proposed start sequence.
- The existing generator rating, operating duty and any available electrical drawings.
- Cable entry positions, termination condition and photographs of the current connection.
- Access for delivery and lifting, plus clearance for ventilation and maintenance.
- Any temporary hire arrangements and the preferred programme for changeover.
- Requirements for transfer equipment, fuel storage, testing and ongoing servicing.
Discuss your 220 kVA standby generator project
Planning a generator replacement for a newspaper printing facility, production plant or commercial site? Blackwell can help you explore Cummins-powered options and discuss the installation requirements with the FW Power team.
Send your required standby capacity, site postcode, existing generator details and preferred timescale. Photographs of the generator position and cable entry will help the team understand the practical questions before preparing a proposal.
Explore the generator range
Compare published generator ratings and specifications in our Cummins range. Cummins-powered Blackwell generators.
Project delivery by FW Power
Blackwell Generators is owned and distributed by FW Power. Read the parent company’s account of the generator supply and installation planning. Visit FW Power’s original project report.