In the energy sector, reliability and the ability to adapt to new sources are key factors to remain competitive. In Brazil, PESA, official distributor of Caterpillar and a leading company in diesel generator sales, identified a strategic opportunity: expanding its portfolio toward generation with biogas generators, a rapidly growing trend driven by the demand for cleaner and more sustainable solutions. To achieve this, it partnered with Multicomercio and Servintel, a specialist in engine automation and control, with the goal of jointly developing a proprietary gas/biogas genset based on a Caterpillar C4.4 diesel engine. This success story demonstrates how Servintel’s specialized engineering can transform conventional engines into certified and reliable biogas generators.
“It was an honor to support the mechanical implementation with Servintel; we achieved a solid and reliable result.” — Eduardo Ombrelino, Technical Director at Multicomercio
The Successful Result: Caterpillar Engine Converted to Biogas with +1000 Validated Hours
Servintel successfully converted a Caterpillar C4.4 diesel engine into a fully functional and certified biogas generator. The results were:- More than 1,000 hours of continuous operation validated in gas and biogas tests.
- Official certification by PESA, confirming the technical feasibility of the converted engine.
- A 100% safe and reliable solution, superior to makeshift market adaptations.
- A new certified product that expanded PESA’s portfolio toward clean energy.
Energy Market Context
The agribusiness sector is experiencing a growing demand for biogas generators as a sustainable alternative. In Brazil, biogas produced from waste represents a unique opportunity to generate clean energy, especially for companies that seek to:- Leverage local renewable sources.
- Significantly reduce operating costs.
- Comply with strict environmental regulations.
The Technical Alliance That Made Success Possible
PESA, Caterpillar’s official distributor in Brazil, identified the lack of biogas generators up to 200 kW in its catalog. The strategic alliance with Multicomercio and Servintel enabled the development of an advanced technical solution that combined the reliability of Caterpillar engines with Servintel’s proven expertise in automation.The Challenge: Transforming a Diesel Engine Into a Reliable Gas Generator
Although PESA had a solid position in the diesel generator market, the company faced a complex challenge: developing biogas generators that met industrial standards without compromising reliability. The project required addressing both specific technical aspects and long-term strategic goals.Project Context
PESA faced the absence of biogas generators up to 200 kW of continuous operation in its portfolio, while the market — particularly in agribusiness and distributed energy sectors — demanded alternatives that could leverage renewable sources, such as biogas produced from animal waste.The need for a safe and certifiable solution avoided makeshift adaptations that compromise reliability.Technical Development Objectives
- Convert a Caterpillar C4.4 diesel engine into a generator suitable for natural gas and biogas.
- Design a safe and robust solution, avoiding makeshift or automotive adaptations that compromise reliability.
- Integrate industrial-grade components with specialized technical support.
- Certify the equipment after a rigorous process of testing and validation.
- Contribute to sustainability by incorporating a renewable, clean energy source.
The Technical Solution: Precision Engineering Applied to Energy Conversion
To achieve the project objectives, Servintel contributed its expertise in automation, engine analysis, and energy project supervision, combining tailored engineering with world-class technology. The solution integrated specialized components with a comprehensive technical approach to ensure the reliability of biogas generators.
Integrated Technology
- Ignition systems, air/gas control, and speed control.
- InteliGen 200: Controller for synchronization and parallel operation with the grid.
- WebSupervisor: Remote monitoring and real-time performance analysis platform.
Servintel’s Contributions to the Project
- Engine and application analysis: full evaluation of the Caterpillar C4.4 for natural gas and biogas operation.
- Specialized technical calculations: precise sizing of actuators, mixer, coils, and spark plugs, ensuring compatibility and efficiency of the system.
- Development of specific parts: design and adaptation of components based on the engine model.
- Comprehensive technical assistance: support in installation, commissioning, continuous supervision, and customer validation.
Project Results: Efficiency, Safety, and Official Validation
After more than 1,000 hours of continuous test operation, the genset met all expected parameters for this type of engine. The results validated both the technical feasibility and commercial impact of the project, setting a new standard for biogas generators in the Brazilian market.Key Achievements
- Official certification by PESA, confirming the viability of the gas/biogas engine.
- More than 1,000 hours of continuous operation in gas and biogas tests.
- A safer and more reliable solution than makeshift or automotive adaptations found in the market.
- Alignment with sustainability goals, generating clean energy from agricultural waste.
- Creation of a new proprietary product, expanding PESA’s portfolio and offering added value to its customers.
Impact for PESA
The diesel-to-gas engine conversion project developed by Servintel generated multiple strategic benefits for PESA:- Expansion into clean distributed generation: PESA entered a growing market with a sustainable value proposition.
- Competitive differentiation: developing proprietary biogas generators allowed PESA to stand out against competitors offering only standard products.
- New product with added value: the solution significantly expanded PESA’s portfolio, providing more profitable and eco-friendly alternatives for its clients.
Project Highlights & Testimonials
“We are very pleased with the solution; it is reliable and meets our needs.” — Luis Fernando Rodrigues, Operations Manager at PESA“It was an honor to support the mechanical implementation with Servintel; we achieved a solid and reliable result.” — Eduardo Ombrelino, Technical Director at Multicomercio
Why Servintel is a Key Partner in the Energy Transition
Servintel’s experience in automation and engine control, combined with its specialized technical approach, positions it as a strategic partner for companies seeking to develop reliable biogas generators. Its comprehensive methodology covers everything from design to after-sales support, ensuring sustainable and certified solutions.Proven Experience in Automation and Control
- Engine control for critical sectors.
- Generation systems for naval and agribusiness industries.
- Biogas generators with industrial certification.
Technical Approach and Continuous Support
- Custom development for each application.
- Process certification and after-sales support.
- Proven technology under industrial conditions.
Technology with a Sustainable Vision
- Adaptation of existing engines to biogas.
- Clean energy generation from waste.
- Automation of biogas gensets.
From Local Innovation to Real Energy Impact: A Replicable Case for Distributed Generation
The alliance between PESA and Servintel marked a milestone in distributed generation with gas and biogas in Brazil. Starting from a diesel engine, we developed a biogas generator capable of operating with clean fuels, certified and validated under real conditions. This success story shows how Servintel’s applied engineering and the use of industrial control systems allow traditional companies to reinvent themselves and respond to the challenges of the energy transition. The validated technical model is applicable to:- Agribusiness plants.
- Electric cooperatives.
- Farms with biogas production.
- Industries with organic waste.
Innovate with Servintel
This diesel-to-gas engine conversion represents the future of distributed generation, combining technical reliability with environmental sustainability.Do you want to develop an energy solution with biogas or natural gas?
Servintel offers complete solutions for diesel-to-gas engine conversion and the development of industrial biogas generators. Our specialized technical approach ensures successful projects with certification and comprehensive support.Discover Our Sustainable Generation Solutions
Servintel’s biogas generators deliver the industrial reliability your project needs. Explore our solutions for gas and biogas conversion!Let’s Talk About Your Project
Contact us today and start your transition to clean energy with certified biogas generators.- Our email: contacto@servintel.com
In summary
How did Servintel manage to convert the Caterpillar C4.4 engine to biogas?
Through technical analysis, specific component sizing, and integration of Huegli Tech technology for ignition and air/gas mixture control.How many hours of operation validated Servintel’s conversion for PESA?
More than 1,000 hours of continuous operation in tests before official certification.What advantages did PESA gain with Servintel’s project?
Expanded its portfolio toward clean energy, achieved competitive differentiation, and created a proprietary product with added value.
