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 

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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. 

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.

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.

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.

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.  

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 

As data centres scale to meet AI-driven demand, the pressure to deliver reliable and sustainable power has never been greater. Across two days of seminars and on-stand discussions, one message was clear: power resilience must be tested and proven.  

Here, Paul Brickman, Commercial Director at Crestchic, shares his key takeaways from the event:  

High-density racks make thermal testing even more critical  

The rise of AI, HPC, and accelerated workloads is pushing rack power densities upward, in many cases exceeding 100 kW per rack. It’s no longer enough to design for high capacity on paper; facilities must prove they can deliver it safely and efficiently under real conditions. 

By simulating the electrical and heat output of high-density racks before live deployment – using a loadbank – operators can validate power distribution, cooling performance, and redundancy strategies without risking downtime or hardware damage. 

Liquid cooling takes centre stage 

Liquid cooling was also a hot topic – and for good reason. As rack density continues to climb, direct-to-chip cooling is an effective way to manage the extreme thermal loads generated by AI and high-performance environments. 

To ensure these systems perform as intended, facilities are turning to water-cooled loadbanks during commissioning. These loadbanks simulate the electrical and thermal output of high-density racks, allowing engineers to test power delivery, heat removal, and system response safely and accurately. 

Resilience requires testing, not just redundancy 

A strong theme at DCW Singapore was that redundancy alone doesn’t equal resilience. Power resilience must be verified, not assumed.  

Loadbank testing allows operators to validate UPS systems, generators, transfer switches, and entire backup circuits under controlled load conditions, ensuring they behave as expected if power fails. Regular testing identifies issues long before they cause an outage. 

Beyond mechanical resilience, many operators are embedding energy storage systems and microgrids to provide independent fallback and grid support. Together, these approaches create a layered energy safety net. However, while resilience is increasingly built into the initial infrastructure, it still must be proven through structured, periodic testing. 

Energy Storage and microgrids are the new normal 

With grids across Asia-Pacific under increasing pressure, the conversation is shifting from “backup power” to “energy ecosystems.” Battery Energy Storage Systems (BESS), hybrid genset solutions, and on-site renewables are redefining how data centres stay online during grid fluctuations or outages. 

Loadbanks play an essential role in testing and commissioning BESS installations – verifying that a system can respond instantly to grid frequency changes, deliver the required discharge rates, and meet its operational specifications.  

Beyond commissioning, loadbanks also support revenue optimisation for operators participating in fast frequency response (FFR) services. By discharging safely into a loadbank, BESS units can maintain optimal charge levels and avoid degradation, ensuring both reliability and profitability. 

As energy storage becomes central to data centre strategy, rigorous loadbank testing will be key to validating both performance and resilience in the face of growing grid volatility. 

Collaboration, skills, and a culture of testing 

DCW Singapore’s power sessions echoed a growing realisation: even the best hardware fails without well-trained teams and disciplined testing routines. Business continuity planning, including crisis simulations and recovery protocols, must be understood by engineers and operational teams.  

Our team can play a key role in building that expertise by delivering training to in-house teams. This collaboration ensures that testing is not just a tick-box exercise, but a genuine transfer of skills that help support ongoing uptime goals. If required, experienced engineers can attend site to run controlled load tests and commission systems, helping to fill skills gaps. By adopting a culture of continuous validation, and building partnerships with skilled partners, data centres can reduce the potentially catastrophic impact of a power failure.  

Final thoughts: Making resilience routine 

Our conversations at DCW Singapore 2025 suggested a shift in mindset: resilience is not a one-time design goal; it’s an ongoing practice. Ultimately, power resilience is about having the confidence that, when the power stumbles, business systems, people, and plans will keep the lights on. Chatting with people from across the data centre sector, reinforced what we already know: true confidence only comes from testing, proving, and improving – again and again. 

The customer approached Crestchic to support the stabilisation of this high-demand, reactive power environment. The LED walls, in particular, contributed substantial reactive power, while the audio system, especially the subwoofers, added inductive elements and rapid transient loads.

Stage power demands fluctuate constantly during a music festival due to dynamic lighting cues, bass-heavy audio peaks from subwoofers, varying LED screen content, as well as intermittent use of special effects, cooling and rigging. Together, these factors cause rapid and unpredictable changes in power consumption, making real-time load management essential to ensure stable, efficient, and reliable power delivery to the stage.

Without intervention, this mix would result in a low power factor, poor generator efficiency, and increased risk of overloading the grid connection.

To solve this, we supplied a 3.4 MVA containerised inductive load bank, designed to absorb excess capacitive reactive power and balance the overall system power factor. This load bank helped reduce reactive energy circulating through the network, relieving stress on the generator and preventing upstream power pollution.

The entire system was monitored and controlled via our MC-LC80 controller, with fibre optic communication ensuring reliable, low-latency control even in a festival environment. This allowed real-time load adjustments and seamless integration with the stage’s changing power demands.

Speaking about the event, Marcus Keunecke, Technical Team Leader at Crestchic, commented: “Thanks to this setup, the main stage at Electric Love ran smoothly throughout the event, delivering flawless performance in both audio and visual production. The customer was extremely satisfied, citing improved power quality, generator efficiency, and peace of mind regarding compliance with grid protection standards. Once again, Crestchic’s expertise ensured that, even at an event of this huge scale, we delivered electrical resilience when it mattered most.”