Newspaper printing runs to demanding production and dispatch schedules. When an established UK printing business needed to replace its ageing standby generator, FW Power brought together generator supply, site assessment and practical installation planning around a new 220 kVA Blackwell diesel generator powered by Cummins.
The project called for more than delivering a replacement machine. Existing cable positions, lifting access and temporary power arrangements all needed to work together, with a clear route from hired equipment to the customer's own standby set.
Standby power for a time-sensitive printing operation
The client produces newspapers in an industrial printing environment, where production windows and onward distribution are closely linked. Dependable standby power forms part of the site's preparations for a mains interruption.
Temporary hire equipment was already supporting the standby requirement. FW Power recommended a new Blackwell Cummins C220 HD, rated at 220 kVA ESP, as the replacement. Before delivery planning, the generator successfully completed its full load-bank test and pre-delivery inspection.
Why the site survey mattered
A detailed survey identified a connection challenge that was not apparent from the generator rating alone. The existing armoured power cables were terminated close to the old machine, leaving little spare movement. The new generator's connection points were in a different position.
Our team assessed whether the existing arrangement could be adapted. The limited cable flexibility and the age of the terminations made unnecessary disturbance an unattractive option. Instead, we developed a connection arrangement that took account of the fixed site cables and the replacement generator separately.
A busbar junction box and flexible final connections
The solution centred on a purpose-built junction box with busbars, positioned near the existing cable entry point. The fixed armoured cables would terminate in this enclosure, with new flexible power cables connecting onwards to the generator. Cable tray and associated components formed part of the proposed installation scope.
This arrangement creates a defined interface between the site's fixed electrical infrastructure and the generating set. It was designed to reduce the need to disturb the existing armoured cable terminations and to make a future generator replacement easier to plan.
Planning the changeover around temporary power
The bespoke junction box had a manufacturing lead time, so the replacement programme needed an interim stage. FW Power planned the removal of the old generator, positioning of the new set and temporary Powerlock cable connections, followed by a return visit for the permanent connection work.
The purpose of this staged approach was to allow the customer's own generator to support the standby requirement while the permanent connection equipment was being prepared. It also offered a route to releasing the hired generator, with temporary cables retained for the interim arrangement.
Delivery, lifting and engineering attendance had to be coordinated as one programme. The project footage below captures the new Blackwell set being handled into position at the facility.
The teamwork behind a generator replacement
Projects like this depend on clear communication between the customer's facilities team, transport providers and engineers. FW Power's contribution included identifying the cable constraints, explaining the available options and developing a practical sequence for the replacement.
That is where the experience of TEAM FW Power makes a difference: understanding the installation as well as the equipment, preparing the generator before dispatch and working through the details that determine how it can be connected on site.
Planning a standby generator replacement?
For printing, manufacturing and other commercial sites, a replacement project should consider the existing cabling, access, lifting arrangements and any temporary power requirement alongside generator selection.
FW Power can help assess the installation, discuss suitable generator options and coordinate supply, installation and ongoing support. Explore our Blackwell diesel generators, installation and commissioning services and generator servicing and maintenance.
Talk to FW Power about your project
Tell us about your existing generator, site requirements and preferred timescale.
