Case Study: Diesel to solar machine conversion - A greener energy solution 

At Tec-Stop, we believe engineering should work with the planet, not against it. Whether it’s airport equipment, agricultural machinery, or heavy-duty industrial systems, switching to sustainable, low-emission alternatives helps businesses stay ahead of regulations, meet vital environmental targets, and reduce lifetime costs. A great example of this is replacing a diesel generator with a solar-electric system - enabling businesses to save money by significantly reducing diesel costs.

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Through rethinking traditional systems and designing intelligent custom wiring solutions that support greener technologies, we help our clients future-proof their operations, without compromising reliability or performance. Our integrated approach delivers a complete solution by combining solar, battery storage, and backup systems, resulting in significant savings for our clients. 

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This case study showcases our latest project: transforming a diesel-powered machine into a solar powerhouse for Aviramp, proving that great engineering can be both smart - and sustainable.

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Introduction: Why convert from diesel to solar?

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As the world shifts toward cleaner, more sustainable energy, solar power is rapidly emerging as a preferred solution for both businesses and individuals. The urgency to reduce carbon emissions and lessen our reliance on conventional fuels has never been greater. Once the go-to for off-grid and backup power, diesel generators are now recognised as significant sources of pollution and greenhouse gas emissions. It’s no surprise, then, that many organisations are turning to greener, cleaner alternatives like solar.

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Switching from diesel to solar power offers a wide range of benefits - including a strong return on investment. By replacing diesel generators with solar systems, businesses can:

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• Significantly reduce fuel and maintenance costs – Solar drastically lowers operational expenses, providing immediate savings.
• Offset installation costs over time - Many companies see a full return on their solar investment within just a few years.
• Minimise reliance on fossil fuels - A solar setup reduces vulnerability to fluctuating diesel prices and supply chain issues.
• Benefit from long-term profitability - Solar systems have low ongoing costs and can deliver decades of reliable performance.
• Improve sustainability credentials - Reducing CO2 emissions supports CSR goals and enhances brand reputation.

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Modern solar hybrid systems - offering the dependability of diesel generators with the efficiency of solar power - ensure an uninterrupted power supply, even during cloudy conditions or peak demand periods. This makes solar a practical and reliable solution for maintaining continuous operations while reducing energy expenses.

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With ongoing advancements in solar technology and decreasing panel costs, the financial case for switching to solar has never been stronger. Companies that invest in solar systems gain access to clean, dependable energy, long-term savings, and the peace of mind that comes with supporting a greener, more sustainable future. By embracing solar power, businesses are not only future-proofing their operations - they’re investing in a cleaner environment for generations to come.

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The client: Aviramp - Accessible aircraft remote stand boarding ramps and bridges

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Aviramp is an independent, entrepreneurial business led by CEO Graham Corfield, specialising in innovative aviation ramps for disabled and PRM (Passengers with Reduced Mobility) access from remote stands.

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Proud recipient of the Queen’s Award for Enterprise in International Trade in 2021, Aviramp is revolutionising the way passengers board aircraft with its unique, height-adjustable remote stand boarding ramps and bridges, delivered worldwide from its UK headquarters.

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The journey began in 2010 when a client noticed their aluminium access ramps for disabled access and commercial use, along with portable aircraft steps they had supplied to the Middle East. When asked if they could design a ramp to help disabled passengers disembark from aircraft parked on remote stands, Aviramp simply answered: “Yes.”

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Originally, Aviramp’s product range was designed to be powered by diesel generators. As Aviramp’s trusted, long-term partner, they approached us to support them on this latest project - designing a greener, more sustainable solar-electric power source, tailored to their unique requirements.

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Overcoming technical challenges

Every retrofit project comes with its own set of engineering puzzles - and this one was no exception. Moving from a constantly running diesel engine to an electric system powered by solar meant we had to rethink how the machine operated at a core level.

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Thanks to our experience in bespoke wiring solutions and electrical system redesign, we were able to tackle each challenge head-on - from voltage conversion and energisation logic to mechanical redesigns that improved efficiency and future-proofed production. This redesign served to enhance the overall system performance.

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Here’s how we made it all work:

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• Voltage adaptation: The controls still required 12V power, so we installed a Victron Energy Orion DC-DC converter to step down from 24V to 12V seamlessly, allowing the new system to connect to existing infrastructure.
• Motor energisation: Unlike a continuously running diesel engine, the electric motor needed to be energised only when in use. We implemented a diode pack to handle this efficiently.
• Standardisation and cost-efficiency: To streamline manufacturing and reduce build time and labour costs, we redesigned all machine variants to share the same rear box plate, allowing us to use common components across models and accept a range of alternative components or solutions.

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The result? A smarter, greener, more efficient machine

What began as a challenge to cut emissions for Aviramp has become a blueprint for smarter, cleaner machinery - both in the aviation sector, and wider afield. By replacing the diesel engine with a clean, quiet electric motor and integrating solar charging, the machine now runs more efficiently, more sustainably, and at a lower cost. This new system helps save on operational expenses and delivers significant saving over time.

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Fuel dependency and maintenance requirements have been significantly reduced - and operational performance and output have gone up. With longer run times, lower emissions, and simplified daily use, the machine is not only easier to operate but robustly built for the long-term.

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Standardising the design across different variants has further streamlined the build process, making assembly faster, maintenance easier, and components more cost-effective.

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This project is a prime example of how smart, sustainable engineering - working collaboratively with a trusted electrical solutions partner - can futureproof your equipment, reduce your environmental impact, and deliver real business value.

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Why choose Tec-Stop for your sustainable wiring solutions?

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With deep expertise in bespoke wiring - from single wire assemblies to complex harnesses, control boxes to looms - plus sustainable total system redesign, solar integration, and advanced energy storage solutions, Tec-Stop is the trusted partner for many businesses ready to transition from fossil fuels to cleaner, more efficient solutions.

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We don’t just rework what’s there - we reimagine it. By combining precision engineering with a forward-thinking approach, we help OEM manufacturers reduce their carbon footprint without compromising on performance or reliability.

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If you are interested in converting your diesel generator to a greener, more sustainable solution, contact Tec-Stop today to consult with our specialists. For more details or to request a quote, visit our website.

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