PP30 Power Pallet

The New Updated PP30 Power Pallet

The PP30 is the latest generation of the Power Pallet biomass gasifier genset system. It represents the largest upgrade of the capabilities and convenience of the Power Pallet up to this point. The PP30 features:

  • Larger, more efficient engine and more efficient generator, which increases the power output to 25kW, vs. the 18kW of the PP20.
  • Standard feature CHP water heating capability, utilizing three stages of waste heat recovery to produce up to 2kW of thermal output per 1kW of electrical load
  • Standard feature grid-tie hardware, enabling all PP30s to integrate into a microgrid with existing power sources or the main grid.
  • Simplified filtration architecture which eliminates the need to sift and prepare charcoal filter media while also eliminating the regular maintenance task of purging the engine.
  • Stainless-steel enclosure and a selectively activated electric cooling fan system to reduce noise.
  • Conical jam-resistant hopper to reduce risk of feedstock jams.
  • Larger ash collector vessel and cyclone dust can.
  • New high efficiency genheads configurable to three phase, at 190-240 / 380-480 V Phase-Phase, 60 Hz or 50 Hz.

Please review the PP30 Basic Considerations to qualify your use case.

PP30 Operation Manual is available on the Support Page.

Note that the Technician’s Handbook available there is based on the PP20, and is currently being updated to include PP30 specifics, although many features are unchanged or similar.

PP30 datasheet

PP30 Datasheet

Why it’s different

See PP30 vs PP20 Comparison Sheet Here

The PP30 Power Pallet is the culmination of our long work to create an expertly engineered, small-scale gasification solution that is realistic for today’s user. While personal scale gasification has long held tremendous promise, the realities of making it work usually prove too much for regular mortals. The high bar of operator expertise and extreme sensitivity to fuel particulars usually combine to make what seems simple in principle, exceedingly difficult in practice.

The Power Pallet has significantly widened this window for success by embedding the needed operator expertise in an onboard electronic brain. These smarts are further extended by a multi-stage gasification architecture and an innovative waste heat capture and recycling system – what we call the Tower of Total Thermal Integration (TOTTI). In traditional systems, hot engine exhaust and hot output wood gas have been problems requiring extra space and cooling components to counter. With the GEK TOTTI, we’ve transformed this waste energy into useful new inputs to the gasification process.  It’s like adding a new free heat source to fix the old and well known thermal challenges of a gasifier.

This Gasifier-Engine thermal integration significantly improves tar conversion, fuel flexibility and general efficiency of the gasifier-engine system. It enables the Power Pallet to solve the tar issue in the reactor, rather than in a large downstream filtering system, significantly reducing the cost, complexity and installation footprint in the process.

Engine and Genhead

The PP30 uses an advanced 4.0 liter 4 cylinder Ashok Leyland engine, spark-fired, but based on their heavy-duty diesel industrial engine.

The engine is mated to a Marathon genhead with automatic voltage frequency and 3x rated amperage at surge for high machinery start capacity.  The genhead is 12 wire so they can be configured to single, split or three phase, in wye or delta configuration and supports all common global voltages: 120, 208, 240 and 400V AC, at either 50 hz or 60 hz.

Actual power produced is highly dependent on the fuel shape, size and moisture content.  Solid biomass is not the consistent fuel source like we assume with diesel or gasoline.  We have used “25 kW” rating although maximum power at 60 Hz is actually somewhat higher.

Optional Accessories:

Continuous Feed Airlock System

To eliminate manual refilling of the hopper, ALL Power Labs is now offering a Continuous Feed Airlock as an option on all Power Pallets. Controlled by an Electronic Control Unit (ECU) with an array of sensors, this system allows a store of feedstock at ground level to be automatically fed, via a standard agricultural feed transport (not included), into the hopper through an automated gate valve on the hopper lid. The horizontal motion of the linear drive operating the gate valve is converted into a vertical sealing force by an innovative leaf spring system, ensuring an airtight seal and reliable operation.Included in the systems are the automated gate valve assembly, the custom ECU, upper and lower level sensors and wiring harness.
Using an open-source processor with an APL-designed circuit board, the ECU reads data from the sensors installed in the hopper and opens the gate valve when the feedstock is low, then signals the motorized feed transport to reload the hopper. Once it detects the hopper is full, the ECU shuts off the feed transport (not included) then closes the gate valve. This smart automation also reads gate position and motor-current sensors to assure safe operation for both operators and the Power Pallet. If problems are detected, the ECU will set the Continuous Feed system into various safe and stable modes and trigger alarms to alert the operator.

CFeed Airlock Datasheet

CFeed Airlock Datasheet


ALL Power Labs provides extensive customer support before and after a sale, online and in person, to help you get your project up and running. This includes:

  • The Power Pallet product documentation
  • Pre-sales consulting available by contacting us through our contact page
  • On-site commissioning and training for a nominal fee