Customization and Modular Design, Rehlko’s Way

Customization for major components of a facility is common in the data center industry, but how customizable is a backup power solution? Two Rehlko experts discussed this question and more in a new Q&A. Ian Wilcoxson, Rehlko Data Centre Channel Manager, and Richard Russett, Rehlko Power Managing Director, sat down to talk all about the topic of genset and enclosure customization — from base models to repeated builds to modularity:

What can you tell us about modular design for backup generators?

Richard Russett (Rehlko): I think the industry talks about the term “modular” often, but understanding exactly what everyone means is sometimes difficult. Everyone has their own perception. We approach it by having key building blocks that we use to build a more customized solution. We have standard designs for different solutions, whether that be for attenuation solutions, power, space requirements, or certain locations. We try to take those standard base designs and adapt them for what any particular customer wants. Sometimes the end product is close to a standard or modular design, but sometimes it can be very different, using those individual components.

What are the types of customization processes that are typical at Rehlko?

Ian Wilcoxson (Rehlko): It starts with the client, really. I'd say we have two or three main types of clients. Small to medium-sized businesses typically don't have a lot of in-house knowledge around customization and modularization. For them, we would be developing the specification using our standard and modular approach. Then we have the hyperscalers, where they have a lot of internal engineering resources and they set the specs. They're quite often, you know, they have their own ideas around pre-engineered components and they have a much better idea of how they want to modularize and phase, which is quite an important point around how you phase a particular larger project.

Could you elaborate on which areas end up being most important for these customers when you're going through this customization process on new generator builds?

Russett: The Rehlko gensets are a fairly standard product, and customers don't tend to customize those very much. They choose a power node, and then we build the solution around that for the customer. Where the customization comes into play is mostly around the solution we build around the genset, predominantly the enclosure, whether it be a noise spec, temperature spec, space constraints, or location.

We're one of the only suppliers that actually does that engineering and manufacturing completely in-house. Recognizing the needs in the market, it's an area we've invested heavily in in recent years and continue to do so. We know from our customers that they see the packaging and building of the solution as being a weak point in the industry in terms of supply chain. Our ability to do that in-house and deliver a complete Rehlko solution is something customers find very appealing. We recently significantly expanded the amount of production and manufacturing space we have for this type of work, with new locations and the ability to increase the volume of work we're able to do in that area.

Are there other Rehlko advantages that you feel are noteworthy that you'd like to mention?

Wilcoxson: One other thing I touched on is that we build in-house. Depending on the site requirements, we do have some third-party packaging as well. These third-party packaging suppliers only work exclusively for Rehlko. We hold the IP (intellectual property) and manage that supplier in the same way as we would in-house. We design and engineer the details around each of those solutions. We're still in control even though it's been effectively produced by a third party. From a QCQA (quality control and quality assurance) perspective, customers can be assured that it leaves a third-party packaging facility in the same way as it would a Rehlko facility.

Any final words?

Wilcoxson: I think what we're trying to do and where we're probably trying to differentiate ourselves is to offer that complete end-to-end solution that's truly managed by Rehlko as a manufacturer: right from assisting with design and engineering at the front end all the way through to controlling the manufacturing process, and then supporting the product when it's actually in its operational environment in the field. We aim to offer that end-to-end process that we, as a manufacturer, fully support the customer with, all the way through the product’s lifespan.

Russett: And also offering a really flexible solution, with lots of options. We know that every site is different, all the site constraints are different. Connect with us, talk to us about your particular site and your particular challenges, and we'll come up with a solution that suits perfectly.

To learn more about Rehlko’s engineering approach, click here. Or, to read about Rehlko’s exclusive in-house enclosures click here.