The newest episode of Rehlko Uncut offers listeners an in-depth look at Rehlko’s rigorous generator testing program, highlighting how the company ensures reliability for customers who depend on uninterrupted power. Senior Project Engineer Justin Stiker and Product Manager for Large Diesel Generators Justin Loritz explain why testing is foundational to Rehlko’s mission-critical product performance.

Loritz begins by explaining that standby generators must work instantly in the event of a power outage, leaving virtually no room for error. Because failure is not an option, every generator undergoes extensive validation before leaving the factory, even after it has been thoroughly tested during development.

New products are subjected to long-duration load tests at varying intensities, cold climate simulations at zero degrees Fahrenheit, hurricane-level enclosure tests, and what is called missile impact testing to meet coastal and high-wind requirements. Both open and enclosed gensets are tested to match the conditions customers will experience in the field. These simulations ensure that performance remains reliable regardless of climate, stress, or installation environment.

A hallmark of Rehlko’s testing approach is the volume and precision of data collected during each simulation. Dozens of temperature probes, pressure gauges, flow meters, and sound monitoring devices are used to capture a complete picture of generator performance.

The episode also examines the role of witness testing, a process in which customers observe their specific generator in operation before it ships. These sessions, held onsite at Rehlko’s facilities or conducted virtually, typically begin with a walkaround inspection to confirm that each unit matches the customer’s specifications.

Customers then watch the generator run inside the production test cell, where output parameters and performance data appear on a live display. After the test, they receive a recorded report that they can reference for their internal documentation. Loritz notes that first-time visitors are often surprised not only by the scale of the testing operations but also by the sophistication of the data acquisition systems supporting them. He emphasizes that the most successful tests are often the quietest ones in which nothing unexpected occurs—because they prove that the development process has done its job.

To listen to the complete episode, which offers even more insight into the engineering rigor, customer collaboration, and forward-looking innovation driving Rehlko’s testing philosophy, click here.