How to reduce generator fuel costs and improve fuel efficiency
Rising fuel prices and sustainability expectations are putting pressure on every site to optimise energy use. Cutting generator fuel costs is achievable without sacrificing reliability by right-sizing equipment, integrating battery energy storage, adopting cleaner fuels, and improving maintenance and monitoring practices. These steps also support emissions targets and help future-proof operations.
Key takeaways
- Oversized generators running at low load waste fuel and increase maintenance costs; right-sizing to your measured demand keeps engines operating in their efficient load range.
- Pairing a generator with a battery energy storage system lets the battery handle light and variable loads, reducing engine run hours, fuel consumption, emissions, and noise on site.
- HVO (Hydrotreated Vegetable Oil) is a drop-in renewable diesel compatible with Aggreko's fleet that can reduce CO2 emissions by up to 80%, NOx by up to 25%, and particulate matter by up to 42%.
- Remote monitoring through Aggreko's Remote Operations Centre tracks load, fuel levels, and faults 24/7, reducing unnecessary idling and helping plan service windows around real usage data.
Right-sizing generators to match your power demand
What right-sizing means and why it matters
Oversized sets often run at low load, which wastes fuel, increases wet-stacking risk, and pushes up maintenance. Right-sizing matches generator capacity to your measured demand so engines spend more time in their efficient operating band. Guidance for critical facilities recommends an electrical load capacity analysis when selecting and sizing generators, not just nameplate estimates.
How load profiling improves selection
Start with a load study covering base demand, inrush currents, diversity factors, and duty cycles across day and night. Profile data helps choose a single set or a staged set-up that keeps engines operating efficiently across variable loads.