PUNCH Power 200

Saving you fuel and money

The PUNCH Power 200 is a cutting-edge flywheel energy system designed to seamlessly connect to your power source. The PUNCH Power 200 can provide a rapid power boost, allowing you do downsize your generator or mains connection without compromising performance. This can significantly reduce emissions and lower your fuel consumption. Experience the future of sustainable power generation with the PUNCH Power 200 and start saving both fuel and money.

Reduced cost of ownership – payback time for one PUNCH Power 200 can be less than one year.

Our fleet of PUNCH Power 200 products have so far saved over 2 million litres of diesel.

One tower crane utilising a PUNCH Power 200 saves the fuel equivalent of 55 cars in just one year.

Custom designed canopy and control cabinet

Canopy and control panel designed to meet industry standards, providing adequate ventilation, durability, and environmental resistance to reduce system downtime.

Comprehensive Control Panel

Utilising an IP67 DSE M840 3.4″ display with a custom PUNCH Flybrid interface for intuitive and robust operation.


The PUNCH Power 200 can be installed rapidly in under 10 minutes, minimising site downtime. A single 125A, three phase IEC form plug links the PUNCH Power 200 to any industrial power source

600 Series Flywheel Module

The flywheel is the heart of the PUNCH Power 200. Capable of rapid charging and discharging, our flywheels are designed to operate for over 10 million cycles without any degradation in performance.

Case Studies

Alimak Hoist

Jaso Tower Crane

Future Olympia



Flywheels are simply a way of storing kinetic energy. Spinning the flywheel faster with an electric motor results in more kinetic energy being stored. The flywheel is run is a partial vacuum, so energy losses are low. When energy is required, the motor applied torque which slows the flywheel and generates electrical power.

A dynamic load is one where the power requirements change throughout the cycle of the equipment. Examples of applications with dynamic loads are vehicles accelerating and braking, lifts in buildings going up and down, and tower cranes moving equipment on construction sites.  Dynamic loads can have characteristics where the load is low for a period of time when the equipment is stationary, but the load increases suddenly when the load is accelerated and can often be negative when a load is lowered or a vehicle is braking.

The opposite of a dynamic load is a static load which remains largely constant for several hours. Lighting and CCTV are examples of static load. Once they are turned on, the power requirements are relatively stable.

Generators on dynamic loads are sized for peak power. In the example of a tower crane, the generator needs to be able to supply a sudden spike of power as the crane operator lifts a load. Once the load is moving, the power requirements are much lower. By providing a boost of power when needed, the PUNCH Power 200 maintains the power supply within an acceptable voltage and frequency range allowing generators to be sized for the normal running power rather than the peak. Operators make three savings as a result

  1. The fuel consumption of a smaller generators will always be lower, due to lower friction in the engine
  2. As a result of lower fuel consumption, the CO2 emissions (and any associated taxes and penalties) will be lower
  3. The cost of renting a small generator is lower than a large generator

For many applications especially where the generator is on light load for a large proportion of the time, the fuel and CO2 savings can be >50%.

If you’re using a generator then the PUNCH Power 200 typically connects to the generator’s busbar, or to a distribution panel with a CE connector on the PUNCH Power 200. In the case of a mains connection it can be connected to a panel. Current clamps can be connected to enable monitoring of the load and additional functionality such as power factor correction.

In all cases, PUNCH Power 200 systems should be installed and commissioned by a person with appropriate training and certification to work on 3-phase electrical equipment.

This depends on a number of factors, but typical downsizings are between 1.5 to 3. On some applications we are able to achieve downsizings up to a factor of 4 i.e. a 400 kVA to a 100 kVA. Customers are provided tools to help assess simple applications, and our team can assist with more complex cases.

Generators meeting the Euro V emissions standard are typically fitted with technologies such as a diesel particulate filter (DPF) and selective catalytic reduction (SCR, which require Adblue® to be used).

These emissions reduction technologies often fail to function as designed when large stage V generators are deployed at very low loads. DPFs can become clogged as the engine exhaust fails to reach the required temperature.  This results in excess fuel being burnt to increase DPF temperature to regenerate the DPF so that it to functions currently or adding a loadbank to keep the load artificially high.  

Downsizing the generator allows it to operate at a higher point of load and can help eliminate these issues without resorting to the use of loadbanks, which whilst effective, cause a significant increase in fuel consumption.

Absolutely. The PUNCH Power 200 requires no physical modification to your generator so can be deployed with any power source which is working on a dynamic load. Alternative fuel generators are rapidly growing in popularity due to the lower emissions profiles.

Load acceptance on generators using gaseous fuel is typically worse than liquid fuel generators because of the way that gaseous fuels are burned.

When a liquid fuel is burned, the fuel is injected into or close to the combustion chamber where it vaporized and is then ignited. This process takes a relatively short amount of time, so the generator can quickly increase or decrease its output in response to changes in load.

When a gaseous fuel is burned, the fuel is first mixed with air before it enters the combustion chamber. This mixture is then ignited. The process to get the right fuel mixture into the engine takes a longer amount of time, so the generator takes longer to increase or decrease its output in response to changes in load.

In addition, gaseous fuels have a lower energy density than liquid fuels. This means that a gaseous fuel generator needs to be larger and have a higher capacity than a liquid fuel generator in order to provide the same amount of power. This also makes it more difficult for a gaseous fuel generator to smoothly increase or decrease its output in response to changes in load.

All these factors mean that the PUNCH Power 200 is very well suited to use on gaseous fuels, as it both reduces the size of generator needed and improves load response on dynamic loads.

Depending on settings, the PUNCH Power 200 can react to load within 30ms. This is much faster than a generator, and contributes to the improvements in load acceptance seen when using our flywheel system.

The amount of energy stored in a flywheel is given by the following  equation

E = 0.5 * I * ω²


  • E is the energy stored in the flywheel, in joules (J)
  • I is the moment of inertia of the flywheel, in kilogram-metres squared (kg·m²)
  • ω is the angular velocity of the flywheel, in radians per second (rad/s)

The moment of inertia is a measure of the flywheel’s resistance to changes in its rotational motion. It depends on the mass of the flywheel and the distance of the mass from the centre of rotation. The angular velocity is a measure of how fast the flywheel is rotating.

The amount of energy stored in the PUNCH Power 200 depends on settings, but is up to 600kJ. This is sufficient to supply 60kW of real power for 10 seconds.

PUNCH Flybrid recommends the following service schedule

The PP200 should be regularly checked for the following:

  • Oil leaks and loose fasteners 
  • E Stop Functionality
  • Cooling Fan operation (all three cooling fans)

The PP200 should be serviced once per year

  • Replace the oil
  • Re-grease the bearings on the motor
  • Thorough check of all bolts, hoses, cables etc for wear etc
  • Replace filters and remove dirt from the system
  • Visual check for any signs of damage e.g. overheating of components within the panel

If situated in a dusty environment, additional actions are recommended

Every 5 years, the system requires a major service. This includes replacement of some components as well as the usual service.

PUNCH Flybrid offers training courses to large fleet operators, enabling them to perform the annual service themselves. PUNCH Flybrid also offers a service kit containing all required parts and consumables.

PUNCH Flybrid offers a 2-year warranty on the PUNCH Power 200. Please contact your local sales team for the full warranty statement.

All PUNCH Power 200 units come equipped with remote monitoring capability, enabling the PUNCH Power 200 location and usage to be accessed at all times. Customers can provide their own sim card, or pay for PUNCH Flybrid to provide data services.

System data is available on a customer portal. User names and passwords can be set up by your after sales team at the time of purchase.

They certainly can be. The flywheel in the PUNCH Power 200 system is designed to have infinite life. Every flywheel is inspected for defects after it is produced. This means the probability of a flywheel experiencing a catastrophic failure is negligible.

We have tested material from our flywheels beyond 10 million charge and recharge cycles, and have observed no deterioration in the mechanical integrity of the material. We have also validated the strength by taking several flywheels to >2 times the normal maximum operating speed which induces >4 times the normal maximum stress. 

The main dangers associated with the PUNCH Power 200 are those typical of high powered 3-phase electrical equipment. As such, the equipment should only be used by persons with appropriate training and certification.


Spec sheet