In the heart of Karachi’s industrial zone, the relentless hum of machinery is the sound of the economy at work. For one major manufacturing unit, this hum is everything. It represents orders fulfilled, deadlines met, and a reputation built on reliability.

But that reputation was put to the test when they received a daunting notification: a planned 48-hour power shutdown by the utility provider for critical grid maintenance. Two full days. No grid power. For a facility running continuous production lines, this wasn’t an inconvenience; it was an existential threat.

Stopping production meant missing crucial export deadlines, breaching contracts, and facing losses running into tens of millions of rupees. They needed a power solution that was not just temporary, but utterly reliable for a full 48-hour generator run-time. The stakes couldn’t have been higher.

This is the story of how ARSL engineered a seamless, continuous power solution that kept their operations running without a single glitch.

The Challenge: More Than Just a Generator

The client’s initial request was simple: “We need a generator for 48 hours.” But our job at ARSL is to look deeper. During our initial site assessment, we identified several critical challenges that a standard rental wouldn’t solve:

  1. Massive and Consistent Load: The facility required a continuous load of 1,100 kW to power heavy machinery, industrial air conditioning, and critical control systems. The generator couldn’t falter or dip even for a second.
  2. Fuel Logistics: Running a 1,100 kW generator for 48 hours straight consumes a vast amount of diesel. How would we ensure a continuous fuel supply without interrupting operations for refuelling?
  3. Zero Tolerance for Failure: A single power flicker could damage sensitive equipment and halt automated production lines, resulting in massive losses. The solution had to be 100% reliable.
  4. Space and Setup Constraints: The designated area for the generator set had specific spatial and ventilation limitations.

This wasn’t just about providing a 48-hour generator; it was about providing a holistic, fail-safe power system.

The ARSL Solution: Engineering Reliability

We moved from being a rental vendor to a power partner. Our solution was built on three pillars:

1. Right-Sizing the Powerhouse

Based on the 1,100 kW load requirement and the need for prime power (continuous operation), we recommended and deployed a 1,500 kVA/1,200 kW Caterpillar generator. This provided a comfortable 20% power buffer, ensuring the generator could handle the constant load without being overstressed, which is crucial for longevity and fuel efficiency during extended run times.

Why Cat®? For a mission-critical 48-hour application, we only trust the legendary reliability and fuel efficiency of Caterpillar generators. Their engines are built for exactly this kind of endurance test.

2. Mastering the Fuel Equation

A 1,200 kW generator running for 48 hours consumes approximately 16,000-18,000 litres of fuel. Our strategy:

  • Primary Fuel Tanks: We deployed the generator with its integrated base tank.
  • Strategic “Mother” Tanks: We set up large-capacity external fuel storage tanks (“mother” tanks) on-site, strategically positioned for easy access.
  • Integrated Fuel System: We connected the external tanks to the generator using certified pumps and filtration systems to create a continuous fuel supply loop. This system was designed to automatically draw from the external tanks once the base tank level dropped, eliminating any need for manual refuelling and ensuring an uninterrupted power supply.

3. The Command Centre: 24/7 Monitoring and Support

Technology was our force multiplier. We equipped the generator with a remote monitoring system that provided us with real-time data on:

  • Fuel consumption and levels
  • Engine performance (oil pressure, coolant temperature)
  • Power output (kW) and voltage stability
    This data was monitored by our team at the ARSL command centre around the clock. Furthermore, we stationed a certified Cat® engineer on-site for the entire 48-hour duration. His role was to perform periodic physical checks and be ready to act instantly if our remote system flagged any anomalies.

The Execution: A Seamless Power Transition

The shutdown began on a Friday at 6:00 AM. Our team was on-site hours earlier for the final briefing and system check.

  • H-1 Hour: The ARSL engineer performed the pre-start checklist. The external fuel system was pressurised and ready.
  • Grid Down (06:00): The grid power cut out. Within seconds, our Caterpillar generator automatically started, picked up the full facility load, and stabilized power output.
  • The 48-Hour Marathon: For the next two days, the generator performed flawlessly. Our remote monitoring team watched the data flow, while the on-site engineer conducted routine checks. The automated fuel system seamlessly managed the immense diesel consumption.
  • Grid Restoration (06:00, Sunday): Grid power was restored. The generator smoothly transferred the load back to the grid and entered its cool-down cycle.

The result? The manufacturing unit’s production lines never stopped. There was no flicker, no downtime, and no damaged equipment. The hum of industry never ceased.

The Result: Beyond Zero Downtime

The success of this project was measured in more than just megawatts.

  • Financial Impact Saved: The client estimated they avoided losses of over PKR 25 million by avoiding production stoppage.
  • Reputation Protected: They met all their delivery deadlines, strengthening their reputation as a reliable supplier.
  • A Blueprint for the Future: The client now has a proven, turnkey solution for any future extended power outages.

What This Means for Your Business

This case study illustrates a vital principle: continuous power is a system, not just a product. It requires:

  • Expert Assessment: Truly understanding your load and site requirements.
  • The Right Equipment: Using industrial-grade, reliable machinery built for endurance.
  • Meticulous Planning: Engineering all supporting systems, especially fuel.
  • Unwavering Support: Providing real-time monitoring and expert human oversight.

Whether you face a planned shutdown or an unexpected crisis, your business shouldn’t have to grind to a halt.

Do you have an upcoming project that can’t afford a power interruption?

Don’t leave your critical operations to chance. Let ARSL design a bespoke, resilient power solution for you, backed by the same level of planning and expertise.

Contact ARSL today for a free consultation and let us show you how we can ensure your power never fails.