Crestchic, the world’s leading provider of load bank solutions, today announced the launch of its innovative 600kW Liquid Cooled Loadbank at Data Centre World, London. The product marks a significant advancement in commissioning technology for the rapidly expanding liquid-cooled data centre market. 

As rack power densities continue to rise, operators are increasingly deploying liquid cooling technologies to manage thermal loads more efficiently. The need for precision commissioning tools has never been greater. Crestchic’s new 600kW Liquid Cooled Loadbank has been purpose-built to meet this challenge, delivering accurate thermal validation and precision electrical testing of liquid-cooled infrastructure at scale. 

Purpose-built for the modern data centre 

The 600kW Loadbank delivers up to 648kW at 415V and has been engineered for the rigours of real-world data centre commissioning.  

At the heart of the new platform is stable ΔT thermal control to ±0.5°C, enabling highly repeatable validation and precision electrical testing of liquid-cooled infrastructure. The unit maintains temperature accuracy to ±0.5°C regardless of flow variation, giving engineers the repeatability and confidence they need during critical testing activities. Comprehensive system protection covers flow, pressure, overload/underload, and thermal shock, safeguarding both the load bank and the infrastructure it is connected to. 

The 600kW platform features a single-vessel architecture, eliminating the need for multi-vessel configurations typically used at this power level. The result is a significantly smaller footprint, making the unit easier to position in space-constrained plant rooms. The compact design also simplifies transport, storage, and on-site handling. With a stackable structure, flush-mounted connections, heavy-duty castors and dual-side forklift pockets, the unit has been engineered for practical deployment on live project sites and can transported double stacked within a standard height ISO shipping container.  

Advanced control and reporting with VCS 

The 600kW platform integrates with Crestchic’s state-of-the-art VCS software, providing a comprehensive digital dashboard with live supply and hydraulic instrumentation data. The software supports real-time monitoring, automatic load profiling and clustering of up to 240 load banks for hybrid air-cooled and liquid-cooled test configurations. Automated compliance reporting via the Crestchic Portal provides audit-ready documentation aligned with key industry standards including ISO 8528-5/22514, NEMA MG1, EN60150, IEEE 141 and ASHRAE G22 standards. 

“The move toward liquid cooling is accelerating as rack densities increase, particularly with AI and high-performance computing workloads,” explains Paul Brickman, Commercial Director at Crestchic. “Our new 600kW Liquid Cooled Loadbank has been designed from the ground up to serve this market, giving commissioning engineers the precision, reliability and control they need to bring critical infrastructure online with confidence.” 

The 600kW Liquid Cooled Loadbank is available for both sale and rental through Crestchic’s global network of offices across the UK, Ireland, Singapore, Germany, Belgium, France, China, and UAE. 

About Crestchic 

Crestchic is a world-leading manufacturer and provider of load bank solutions, with decades of experience supporting the power generation, data centre, marine and defence industries. For more information, visit www.crestchicloadbanks.com 

Media Enquiries: Laura Wilks |  l.wilks@crestchic.com | 07828953758 

Ends 

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Founded in Burton in 1983, Crestchic has developed its UK operations in the town over four decades, moving to its current Centrum 100 headquarters in 1998 and continuing to expand locally as demand increased. In mid-2021, the company invested in a new factory, increasing its footprint by 60%. The expansion delivered strong operational results, including a 150% increase in production output, a doubling of the company’s rental fleet, and headcount growth from 175 to 250 employees.

However, with operations now operating across three neighbouring sites, and demand growing globally, the move will improve efficiency and create room for further expansion. The move to Centrum Logistics Park allows Crestchic to bring manufacturing, engineering, and logistics operations together in a single, larger facility.

Chris Caldwell, MD at Crestchic, commented, “Demand for power testing solutions continues to grow across multiple sectors, and while our previous expansion delivered strong gains, demand has continued to grow. This move allows us to future-proof our UK manufacturing base, improve operational flow and create capacity for further expansion while retaining the skilled workforce we have built in Burton.”

The lease for the new site has now been signed, with the relocation planned over a 12-month phased programme. This timeline will enable Crestchic to develop a world-class manufacturing facility purpose-built for precision electrical engineering, supporting higher-quality output and long-term operational resilience.

The new facility provides high-clearance industrial space, expanded loading capacity, and improved logistics circulation, supporting higher production throughput and accommodating the company’s growing rental and service divisions.

With the new footprint more than double than the company’s current Burton facility, Crestchic plans to increase production output by a further 75% in the coming years.

The building also aligns with company sustainability objectives, featuring solar PV generation, high energy efficiency standards, LED lighting, rainwater harvesting, and electric vehicle charging infrastructure, helping reduce operational energy consumption and emissions.

The move positions Crestchic to meet continued demand growth across data centre, power generation, renewables and industrial sectors while strengthening the resilience of its UK manufacturing operations.

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Grid instability is a growing risk 

According to Uptime Institute’s report, “Uptime Intelligence expects resiliency to re-emerge as a major area of focus and concern for the industry.”  

Ageing transmission infrastructure, electrification, intermittent generation, and the explosive growth of AI computing are putting increasing strain on power grids. In September 2025, the US Department of Energy (DoE) warned that grid power outages could increase one hundredfold by 2030. The US is not alone. In April 2025, Spain and Portugal were hit by one of the largest blackouts recorded in Europe in decades. In that same year, hundreds of smaller blackouts were caused by a myriad of failures and extreme weather events, suggesting that Europe’s electricity system is also at risk.  

With sources pointing to more frequent disturbances, voltage fluctuations, and long-term outages, data centres that once expected rare grid failures must now plan for more regular outages. 

Most data centres overcome this risk by installing backup generators. However, with frequent grid fluctuations and outages putting greater stress on critical power systems, ensuring the reliability of the generator is critical. This changes the role of testing. As grid risk rises, load testing becomes a frontline defence, not a compliance checkbox.  

From “maintenance asset” to strategic resilience tool 

While large outages are becoming less likely relative to industry growth, Uptime Intelligence data shows that, when failures do occur, their consequences are more severe. This shift necessitates a new approach to generator testing.  

While using a load bank to test generators has always been critical in terms of maintenance – testing alternator housing, windings, bearings, controls and cooling systems, and avoiding wet stacking – the extra pressures of grid instability and the rise in high-density infrastructure mean that operators must go beyond maintenance.  

Where many operators may previously have relied on testing once or twice a year, testing should now include scenario-based testing, including black starts, ATS transfers and N+1 failures. When backup systems consist of several generators, testing is also a vital step in validating synchronised or parallel systems, including verifying that they start automatically, synchronise, and support failover mechanisms. Tests should also assess how generators would perform in the event of a partial power failure.  

Proper loadbank testing can provide data that can directly influence board level decisions around resilience, investment, and risk planning. When asked, “How confident are we in our backup power?” Load bank results become the only credible answer. 

On-site power growth 

As grid capacity tightens, and fears of systemic failure mount, more data centres are investing in prime power systems, gas turbines, hybrid generation and shared power infrastructure across campuses. While becoming independent of the grid and adding redundancy may reduce reliance on large backup systems, new generators and power systems also require careful validation.  

Full system testing should be undertaken during commissioning, to confirm that the system – whether diesel generators, gas turbines or other power sources – performs as expected under real operating conditions. This includes validating load sharing and synchronisation in multi-generator or hybrid generation systems, as well as checking system settings and components to ensure safe transitions and fault response. Equally, thermal and cooling systems should be tested to confirm they can handle operations without overheating. Additionally, fuel systems must perform flawlessly to deliver clean and polished fuel for hours upon end, from large fuel storage systems across a range of ambient temperature throughout the year.  

None of that can be done meaningfully without load banks. In a world of multi-megawatt data centres and off-grid power generation, skipping load testing is effectively commissioning in the dark. 

Compliance moves centre stage  

As data centres create more energy on-site, prime power, built-in redundancy and battery storage mean that some facilities are actively supplying the grid through demand response arrangements. This move from data centres as passive consumers to “grid interactive” resources are likely to bring a new level of compliance. Many grid-interactive sites are being asked to meet new grid connection rules, including performing and documenting commissioning tests, as well as regular testing, to ensure safe grid-parallel operations and reduce risks.  

 As compliance requirements tighten, load bank testing is likely to become a regulatory enabler, demonstrating proven reliability.  

The need for full load 

Of course, while new pressures abound, we can’t overlook the age-old issue of wet stacking in backup generators. Wet stacking usually occurs when engines operate significantly below their rated output level, which is common in backup scenarios. This excessive no-or-low-load runtime causes a buildup of unburned fuel deposits around the combustion chamber, injector nozzles, piston rings, turbocharger, and exhaust. This, combined with condensed water, results in carbon particles and moisture gathering around the exhaust system. Potential outcomes include reduced power, increased emissions, and higher operational costs.  

Regularly running the generator at full load during load bank testing can resolve these issues. If the generator is used below the rated output level on a regular basis, pairing it with a load bank more permanently will prevent “wet stacking” from happening. Without load banks, generator failures often appear for the first time during a real outage, when it’s already too late. 

The bottom line: Load banks are still mission-critical 

As power resilience remains a real risk for data centres, load bank testing remains the backbone of a credible uptime strategy. As well as their ongoing role in testing whether backup power is “outage ready” and preventing equipment damage, load banks are increasingly important in supporting tiered resilience strategies and de-risking on-site power plants.  

In a world of unstable grids, AI-power consumption, and high uptime targets, backup power that hasn’t been tested using a load bank isn’t really backup power at all. 

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Magic for Engineering Works installed two 500 kVA Perkins/Stamford diesel generator sets, providing synchronised backup power for the control tower. However, operating generators at low load can lead to reduced efficiency and mechanical issues, such as carbon buildup—a challenge that requires a smart, responsive solution. To address this, a 200kW Crestchic load bank was integrated into the power system to maintain optimal generator loading and ensure long-term reliability.

The Crestchic load bank was configured to operate in Trakker control mode, automatically tracking the site’s load and applying additional power as needed to maintain a healthy minimum load on the generators. Whenever the total generator load dropped below 30%, the load bank would seamlessly activate, applying additional resistive load to keep the engines running within their optimal performance range. Once the system load exceeded 30%, the load bank would quietly disengage, all without human intervention.

“Running a generator on low load for extended periods can lead to a range of issues — from inefficient fuel combustion and carbon build-up to premature engine wear,” explains Isabella Xu, Technical Sales Manager at Crestchic. “In mission-critical facilities like an air traffic control tower, those risks are unacceptable. A properly configured load bank ensures the generator operates within its optimal range at all times, ensuring it operates reliably if called upon.”

Using the included control system, the load bank can also be operated manually. By switching control settings on the panel, the operator can select and apply any desired load level. This flexibility enables the system to be used for both routine maintenance testing and automatic load management during operation.

With Crestchic’s load bank at the heart of the system, the airport benefits from reliable, efficient, and intelligent power management. This ensures that critical backup power operates at peak performance, keeping Cairo’s air traffic control operational no matter what happens on the ground.

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While the immediate impact of Storm Goretti leaves little time for last-minute preparation, it serves as a timely reminder that power-continuity planning is not a one-off exercise.

Paul Brickman, Commercial Director at Crestchic, explains: “To be truly robust, power continuity plans must be created, tested, reviewed, and refined regularly. Severe weather events expose weaknesses quickly. Businesses that have not routinely assessed their emergency procedures, power resilience and backup power performance may already be feeling the consequences. The message is clear: long-term preparation remains the most reliable defence against weather-related power cuts.”

While many businesses have already taken the step of investing in backup power, experts at Crestchic warn that having backup systems in place is not enough unless they have been properly tested. Generators, UPS systems, and switchgear must be tested under real-world conditions to ensure they perform if the power fails.

Crestchic has shared six key recommendations to help businesses prepare for potential winter outages:

1. Conduct a risk assessment to identify how a power loss might affect operations.
2. Install a backup power system to maintain supply in critical areas.
3. Test new and existing backup generators regularly to ensure they function properly when needed.
4. Ensure that generators are run on full load regularly, to avoid “wet stacking”, efficiency issues, and potential failure.
5. Perform regular inspections to check coolant, fuel, oil, and battery health, while also looking for any signs of leaks or wear.
6. Train staff on the importance of maintaining backup systems, responding to power outages, and contacting the right people in case of issues.
7. Remember this is not a one-off process – risk assessments and plans should be tested, reviewed and revised regularly.

Power failures can have serious consequences for businesses of all sizes, from lost revenue and downtime to safety risks, data loss and reputational damage. Even brief outages can disrupt operations and customer service, particularly during severe weather. The outages caused by Storm Goretti have underscored the importance of reliable power resilience for every organisation.

For advice on ensuring your generator or backup power is fit for purpose and will protect your business during a power outage, contact the team.

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A total of 1,550 rack-mounted load banks were installed on-site, completing 8 MW of testing. The same set of equipment was subsequently used for Phase 3 of the project, which was also completed successfully.

Additionally, 3300kVA load banks were deployed for the testing and commissioning of various UPS systems and generators throughout the site. To enhance mobility and efficiency, these load banks were mounted on trailers, allowing the customer to move them around the site as needed easily.

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We were delighted to take home both the Business Growth and Strategy Award and the Innovation and Technology Award, recognising our commitment to providing industry-leading solutions worldwide.

Business Growth and Strategy Award

The Business Growth and Strategy Award, was highlighted by the judges for “a clear growth trajectory supported by innovative use of data, product diversification, and international expansion”. The panel praised our confident leadership and strong strategy, noting that it continues to deliver measurable success on a global scale.

This achievement reflects a transformational period for Crestchic. In the last three years, Crestchic has invested heavily in people, premises, and product development, accelerating growth across the entire organisation. This has been underpinned by major operational expansion to meet growing customer demand: manufacturing output has risen by 150%, and the rental fleet has nearly doubled.

Strategic global expansion has also been central to this success. Crestchic has opened new rental facilities in Belgium and France and strengthened its long-established Middle East footprint through the acquisition of Gulf Incon. Looking ahead, Crestchic’s ambitions remain bold, with plans in motion for further global expansion.

Innovation and Technology Award

We also triumphed in the Innovation and Technology category. The award acknowledges the development of Crestchic’s Versatile Control System (VCS), which judges described as “a creative and practical innovation that elevates operational performance and sets a new benchmark for the industry”.

VCS is a ground-up rebuild of loadbank control software designed to meet the growing complexity of global power testing environments. As highlighted in the entry, it enables users to test, control, and manage up to 200 loadbanks simultaneously, either individually, collectively, or in clusters, representing a major step forward for large-scale data centre testing.

Chris Caldwell, Managing Director at Crestchic Loadbanks, commented: “Winning two AMPS Awards is an incredible achievement and a real testament to the dedication and expertise of our team. Our strategy, innovation, and product development are driven by a commitment to supporting our customers and building our business. We are proud of what we’ve accomplished and excited about what’s ahead.”

Hosted by stand-up comedian Alfie Moore, the ceremony celebrated innovation and collaboration across the power sector. We are incredibly proud of our team and grateful to AMPS and the judging panel for recognising our ongoing commitment to advancing load testing technology worldwide.

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Data Centre Growth in Ireland  

Ireland’s status as a global hub for data centres continues to grow, supported not only by the expansion of major players such as Amazon, Google, and Digital Realty, but also by the rapid development of the local supply chain. This ongoing investment across the wider data centre ecosystem makes Ireland a key focus area for Crestchic, as demand for resilient, high-performance power infrastructure continues to rise. 

The power conundrum  

The country’s data centres have seen electricity consumption surge by more than 530% since 2015, according to the CSO, and EirGrid forecasts that by 2032, data centres and other large energy users could account for 30% of Ireland’s total electricity demand. In response, the Commission for Regulation of Utilities (CRU) is reviewing the connection of new facilities to the grid. Its proposed framework could require operators to provide on-site generation or storage capacity to match demand, with a stronger emphasis on renewable integration—a move designed to reduce strain on the national grid and encourage sustainable growth. 

 “This rising demand underscores the importance of power efficiency, stability, and reliability within the sector,” said Paul Long, Business Development Manager at Crestchic Ireland Ltd. “Wherever that power comes from, whether the grid, renewables, BESS systems, or local generation, there remains an ongoing need for data centre operators and their supply chains to validate and optimise their systems, ensuring that when power is needed most, it performs exactly as intended.” 

Loadbanks and power testing solutions 

Crestchic manufactures AC and DC loadbanks to provide accurate and stable electrical test loads for the commissioning and maintenance of emergency power systems. Their product portfolio includes Resistive loadbanks from 20 kW to 7,000 kW; resistive-reactive loadbanks from 50 kVA to 6,250 kVA; medium-voltage loadbanks capable of up to 36 kV; DC loadbanks for battery discharge testing; and heat-load testing solutions for data centres.  

 At the event, Crestchic will showcase its latest loadbank solutions for data centre commissioning and maintenance. This includes the new 200 kW model, which is ideal for Integrated System Testing (IST) due to its compact design and high power density. We will also present a water-cooled loadbank designed specifically for server hall testing, offering efficient and reliable performance even in high-temperature environments.  

 Find out more about the event at https://www.datacentres-ireland.com/. We also invite you to visit the Crestchic team at stand 427 to learn more about our solutions and how we can help you address the power challenges in data centre operations.  

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The Project of the Year Award aims to highlight projects that have exemplified excellence, ingenuity, and forward-thinking, setting new standards for the industry. From original approaches to complex challenges, to projects demonstrating scalability, adaptability, and sustainable practices, the award highlights the diverse ways in which organisations continue to push the boundaries of what is possible. 

Chris Caldwell, Managing Director at Crestchic, commented: “The Project of the Year Award provides a valuable opportunity to highlight projects that set new standards for the industry and serve as inspiration for others. As long-standing members of AMPS and recipients of the AMPS Company of the Year Award in 2024, we understand first-hand the value of these awards in recognising excellence across the sector. With colleagues from across the industry gathered together, it is vital to recognise and reward success, share best practice, and celebrate the talent and expertise that continue to drive power generation forward.” 

The 2025 AMPS Awards for Excellence will take place on Thursday, 13th November 2025, at the Lowry Hotel in Salford. The evening will begin with a Networking Drinks Reception, followed by a Black-Tie Gala Dinner and the much-anticipated awards ceremony, where leading companies and individuals will be recognised for their contributions to the industry. 

For further information, to purchase tickets, or to submit an award entry, please visit amps.org.uk 

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