
Breaking Free from Generator-Only Power: An Intro to Hybrid Generator Systems
For decades, the generator has been the backbone of power production in remote locations, construction sites, and critical infrastructure backup. It’s a dependable workhorse, but it comes at a cost—high fuel consumption, regular maintenance, noise, and a significant environmental footprint.
Meanwhile, hybrid power systems are redefining energy efficiency and reliability by combining traditional generators with advanced battery storage, inverters, and renewable energy sources. These systems provide clean, uninterrupted power with far less fuel consumption and much lower CO2 emissions.
At Intelligent Controls, we support manufacturers to develop best-in-class power conversion and energy storage solutions. We help pioneer the use of innovative products like Hatz generators, Pylontech and Victron batteries, and Victron inverter/chargers into new and creative applications.
Together, these components create a robust hybrid energy architecture that cuts costs, improves sustainability, and keeps operations running smoothly in any condition.
So, What is a Hybrid Power System?
Let's clarify some key terms used in this and other articles.
A hybrid power system combines multiple power sources—including generator power, solar, stored battery power, and the grid—to create a more effective power delivery strategy than any single source could achieve alone.
Each energy source has its strengths and limitations. In a hybrid system, these sources work together to maximize benefits while minimizing drawbacks.
A hybrid generator system is an advanced approach to power generation that combines battery storage and inverter systems with generator power for improved load management.
Here’s how it works:
1. Generators Operate at Max Efficiency
Instead of running constantly, or running at non-optimal rates, a generator in a hybrid power system is run only when needed and only at its peak efficiency. Diesel generators, like the Hatz fiPMG, use stored fuel to charge batteries directly through a built-in power controller, significantly improving charging efficiency. This setup also helps minimize the inherent inefficiencies typically found in oversized generators. Fuel savings of 50% or more can be achieved by right-sizing the generator.
2. A Lithium ESS Battery Bank Evens out the Flow of Power
Communicating LiFePO4 Batteries, like those from Pylontech or Victron, store energy for low-demand periods, reducing generator runtime. During peak usage, these batteries provide additional power, enabling the use of smaller and more efficient generators. They offer improved longevity, faster charging, and higher efficiency than traditional lead-acid systems. Advanced lithium batteries communicate with Victron power systems via Victron's DVCC function, delivering 15–20% better charging performance and a host of long-term benefits that are above and beyond what is available from most batteries with this same lithium chemistry. For more, read Bad, Better, Best: Battery-Inverter Communications & Compatibility.
3. Inverter/Chargers Allow Stored Power to be Used
A reliable inverter/charger forms the core of every hybrid system. Victron's inverter/chargers provide smooth transitions between power sources while communicating with many sources like solar and generator power to maintain an uninterrupted supply while maximizing efficiency. For more, Read Victron’s PowerAssist Function Explained.
4. Alternative Energy Adds Value to an Already Reliable System
Adding solar or wind to your hybrid system directly reduces your power consumption from traditional sources. In favorable weather conditions, you might eliminate the need for generator or grid power entirely. A system that embraces alternative and conventional power sources delivers optimal value and makes a robust system even more reliable.
Note: A Battery Energy Storage System (BESS), or simply, an Energy Storage System (ESS), is a battery storage bank, usually lithium, that stores power for later use or during periods of high demand. This is a core component in any hybrid power system, whether grid-tied, off-grid with a generator or any other multi-source configuration.
Why A Generator System Should be Hybridized
Hybrid generator systems solve many of the problems that have plagued generator-only setups:
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Fuel Efficiency: Cut fuel use by up to 80%—or even 100% with solar or grid inputs. Less frequent refueling runs mean lower costs and less downtime.
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Lower Maintenance: Generators run less often, reducing wear and tear, while advanced batteries and inverters require minimal upkeep.
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Quieter Operation: With batteries handling most of the load, you’ll experience far less noise—a big win for urban sites, job sites, concerts, food trucks, etc. “Quiet hours” can even be scheduled with the system running automatically to avoid generator usage overnight.
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Environmental Impact: Reducing generator runtime slashes CO2 emissions. When paired with solar, you can achieve near-zero emissions.
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Reliability: In a hybrid generator system you no longer have to rely on the generator for power 24/7. This means that you don’t lose power during routine maintenance, in cold weather, or if your system runs low on fuel.
Applications That Shine with Hybrid Systems
Hybrid power systems aren’t just for one industry—they excel wherever reliable power is needed, including:
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Remote Locations: From wildland fire camps to rural residences to off-grid research stations, hybrid systems reduce reliance on costly fuel deliveries, and can replace reliance on continuous grid power.
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Critical Infrastructure: Hospitals, commercial locations, and telecom sites benefit from uninterrupted power and reduced emissions.
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Security Trailers and Traffic Safety Equipment: When system downtime is not an option, hybrid power systems with communications offer incredible reliability and remote monitoring capabilities.
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Emergency Vehicles: Critical equipment on emergency vehicles like ambulances and fire trucks can reduce engine idling by using an onboard ESS system, extending operation times and reliability.
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Mobile Businesses: Delivery vans, mobile food trucks, refrigerated trailers, mobile clinics, professional vehicles, and mobile research vehicles can all benefit from onboard power that is charged via an alternator or a supplemental generator.
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Home Backup: Grid-connected residential or commercial properties with hybrid power systems can maintain well pumps, septic systems, internet, heating, etc, during extended power outages.
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Construction Sites, Light Towers, On-Site Power, Etc: Quiet operation and cost savings make hybrid systems a perfect fit for temporary or semi-permanent setups.
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Urban Events: Silent, efficient power that blends seamlessly into residential or event settings like music festivals and outdoor theater performances.
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Disaster Response: In areas with limited access to fuel or high transportation costs, the long run time of hybrid power systems offers a tremendous advantage. With the generator running only when needed, this means the same volume of fuel can provide up to 80% more uptime than a traditional genset.
Getting Started with Hybrid Systems
While the traditional generator rental market in the United States is valued at 2.58 billion in 2023, the number of hybrid generator options is still small with few affordably priced options. The opportunity is there. What are the next steps?
1. Get up to Speed
Intelligent Controls has been tasked with sharing best practices from the well-established (and profitable) European hybrid generator market. Together with Victron Energy, Pylontech, and Hatz, we’re leading a hybrid generator education tour to bring real hardware and proven solutions to your team. Get first-hand experience with several product integrations that have proven valuable for the hybrid generator market and which directly impact cost, reliability, and performance. Visit the PowerTrip landing page to learn more and to sign up for a training near you.
2. Assess Current Costs and the Value to Your Customer
Hybrid generator systems can never harm a site’s performance - in almost all cases, it’s a net benefit. To understand the immediate and long-term cost savings of hybridizing your power system, you need to understand the energy consumption patterns and the actual costs of the existing system: maintenance, fuel, and operational costs.
This analysis often leads to interesting value propositions specific to your customer. While there might be many distinct advantages to a hybrid system, one or two are likely the most important to the end user. Ex: Consider a large generator that currently runs at low-capacity overnight in a residential area. Shutting it off during these hours could be crucial for reducing both fuel consumption and noise. In contrast, a similar system powering critical communications or monitoring equipment would prioritize a design focused on continuous operation with zero-downtime. Being able to add value to specific use cases is part of what makes hybrid generator systems so interesting to develop.
Our team has created a cost analysis tool to help you estimate the cost-saving potential of a hybrid solution. To learn more, send a message to our team or contact me directly at reid@intelligentcontrols.io.
3. Size your System Correctly
Don’t feel you have to reinvent the wheel on hybrid power systems. Executing in your industry means right-sizing for your customers and focusing on their needs. Having the fundamental system design and choosing the right building blocks is critical to getting started.
In a hybrid system design, we are balancing power requirements with battery capacity while adding the right alternative energy to maximize value for your operational scenario. Beyond these main variables, there are a ton of smaller program-based customizations that we can help you develop that will enable your customers to better visualize their savings and better monitor and control their systems.
4. Use Proven Equipment
Use the highest quality equipment you can. This is the best way we know of to insulate your design from critical failures. Predictable results come from predictable quality and support. We use and recommend a particular product mix because of its reliability, the flexibility it allows when designing systems to spec, and the advanced communication capabilities that enable core components to work together in harmony.
When working with Victron and Pylontech components, the battery and inverter capacity can be scaled up to support very large systems using the same underlying control and monitoring systems. Bringing in the advanced generator communications of Hatz further improves this synchronization and reliability.
5. Take Remote Monitoring Seriously
Remote monitoring is like telemedicine for power systems. It’s what allows you, as the system owner or manager, to verify the system's performance and monitor all connected components within. Your ability to view and adjust settings specific to the batteries, inverters, or generator is not just a nice add-on, it’s a massive time saver for small and large businesses alike that are looking to cut waste and exceed customer expectations for timely service and tech support. The labor savings associated with embracing tools like Victron’s remote monitoring are not small and the value only increases as the number of installed systems increases. For more on this, read Remote Monitoring Capabilities of Victron-Pylontech Power Systems.
6. Pick Your Support Network
Work with partners that can support you. In basic terms, this means partners that can help you develop custom solutions and navigate all the possibilities to find the right products for your application. We expect our troubleshooting solutions to be a phone call away, and so should you.
Why work with Intelligent Controls?
Intelligent Controls provides the best possible components, design solutions, and technical support to teams implementing advanced power systems. Our expertise in DC power systems, lithium battery storage, and generator integration ensures you have the right building blocks for your hybrid power system. We’re here to get you started, answer questions and offer suggestions that make your R&D process as smooth and efficient as possible. Once you’re in production mode, we’ll support you with the training or the outside perspective you need to troubleshoot issues as they arise, evaluate the system's feedback, and make iterative improvements so you can execute with confidence.
The Future of Power is Here
Hybrid generator systems are transforming how we think about energy. They’re cleaner, smarter, and more efficient—giving you the reliability of a generator without the drawbacks of a generator-only system. We think these systems have a very bright future and are excited about our role in encouraging growth in this market.
If you’re ready to step into the future of power, we’re here to help. Visit us at our upcoming training events or get in touch Intelligent Controls to learn more about how hybrid systems can work for you.