Broadcrown a generator of success

Broadcrown is one of the world’s largest manufacturers of generating sets, offering a wide range of standard and bespoke power solutions to the worldwide market, from 10kVA to 5000kVA.

With its corporate headquarters and two state-of-the-art factories located in the UK, Broadcrown undertakes all aspects of set design, project management, manufacture, installation, commissioning and maintenance of generating sets and control systems.

Broadcrown was established in 1976 and from its inception the company has recognised the special and constantly changing needs of the international power generation market, and has grown its skills, technology and manufacturing base to become a market leader both in capability and products.

Over the last ten years, Broadcrown has been developing its export ranges, improving canopy designs while reducing cost, and now the company has a product range it can be proud of. Today, orders are running at record levels and the business is continually increasing its market share. As a result, Broadcrown has had to increase the size of factory capacity in Newtown to meet the increased production levels. The company intends to continue with its strategy for growth and plans to double current volumes over the next three years.

All of Broadcrown’s manufacturing is undertaken in the UK. Generating sets below 550kVA are manufactured in a dedicated 30,000 sq ft plant in Newtown, Wales. Larger generating sets (and custom built units up to 5000kVA) are designed and manufactured in a purpose built 28,000 sq ft factory at the corporate headquarters in Hixon, Staffordshire. Both factories have been specially designed and equipped for generating set manufacture utilising the latest manufacturing techniques.

Also based at Hixon is the company’s Projects Division. Broadcrown undertakes all aspects of set design, project management, manufacture, installation, and commissioning for major UK projects. Throughout its long history Broadcrown has been involved in many high profile projects and built up an enviable client base across a large selection of industries such as hospitals, banks, data centres, water authorities, TV and radio transmission, retail, and medical research facilities.

Quality has been a fundamental requirement of factory and product design for Broadcrown, the objective being to ensure that the highest quality standards are maintained and that all systems and production methods assist in meeting this objective. Broadcrown’s compliance with this commitment has resulted in achieving the ISO 9001 quality certification.

To compliment its high quality, and to ensure the company is meeting its clients’ demands, Broadcrown places a large emphasis on meeting and exceeding its customers’ exact requirements. To ensure clear focus on the specific needs of its customers, such as service support or the specialised needs of large projects, Broadcrown is structured into several operating divisions each with its own dedicated staff and resources, available to provide the highest levels of customer satisfaction. These high standards are reflected through a growing international network of distributors providing local sales and support for Broadcrown products in all continents. In addition, the company has established its own regional support centres in Singapore, West Africa and Miami, to provide sales and technical support to assist the distributor network.

With significant investment in new production facilities and developing a customer-focused organisation, Broadcrown has been able to blend design excellence with production efficiency to produce power generation systems that fully meet the precise standards of design, installation, operation, performance and support that customers worldwide deserve, whatever their power needs. To fully satisfy these needs, Broadcrown has developed an enviable reputation for the technical excellence of its staff, combining an extensive skill and knowledge base with the latest design technology to create unrivalled products that meet the need for reliable and efficient power generation.

Over the last few years, Broadcrown has developed key strategic alliances with major subcomponent suppliers. The organisation’s reputation as a renowned supplier of generating sets depends on the performance and reliability of the components used in the manufacturing process. As a result of this, certain criteria’s have to be met in order for partnerships to form. These include, advance notice of product introductions and engineering changes, unrestricted access to manufacturers field service network for key components, continuity of supply in periods of high demand, and competitive pricing – ultimately benefiting the end client. Strategic suppliers include sources of major components such as engines, alternators and cooling packages.

Today, Broadcrown has combined experience and technology, whilst seeking the active involvement of the major component manufacturers, to ensure the best matching of components and suitability for purpose. This approach has enabled Broadcrown to produce an exceptional range of standard products and recognising that, as power applications become larger and requirements become more specialised, the company also offers a further range of bespoke products.

The full product range includes generating sets for standby, prime and baseload power applications, together with an extensive range of control systems to cater for basic key start and automatic mains fail operations, generator and mains synchronising applications, as well as sophisticated load management control systems incorporating dual redundant PLCs. The product range is available in different formats either as an ‘open set’ for installation within a dedicated plantroom or suitable for external use within a sound attenuated canopy, weatherproof acoustic enclosure or ISO style container.

While standard products may meet the needs of most consultants and end users, Broadcrown recognises that some applications require special attention, consideration and custom-design, which may involve stringent noise control, restricted space, remote cooling arrangements or special voltages. In these situations Broadcrown designs the product to meet the application’s exact requirements. The company will supply total turnkey power solutions, covering all aspects from initial site survey to commissioning, including project and site management.

Broadcrown also offers all site services, including mechanical installation, electrical installation, commissioning, service sales, aftersales support, spare parts and ongoing maintenance. Broadcrown Site Services employs in excess of 50 members of staff, all controlled from its headquarters in Hixon, Staffordshire. Each function has a manager and support staff. All mechanical and electrical installation teams are fully conversant with construction site protocols and safety requirements. The installation teams operate from fully equipped vehicles and carry all required health and safety documentation.

The commissioning engineers are each equipped with the necessary tools and software to interface with all of the Broadcrown preferred PLC and HMI operating systems. The after-sales department is there to provide total technical support and back up to all customers, available 24/7 under special contract.

After 30 years of successful trading, Broadcrown is now looking to expand its export market. Over 60 per cent of Broadcrown’s turnover is from export, which is expected to rise to 75 per cent over the next two to three years. The demand for power is rising globally as developing countries are driving for growth and developed countries are becoming even more dependent upon quality uninterrupted power supplies. Broadcrown believes that this growing export market will provide many opportunities for the company in the future and will be key to its long-term success.


Products: Generators
Sites: UK, Singapore, Miami and Nigeria
Employees: 180