Regency Plastics

At a Glance
• System Configuration: 6 × C65 Grid Connect Capstone Microturbines with controls
• Annual Generation: >2,000 MWh/year of clean, grid-synchronized electricity
• Financial Impact: ~$300,000 / year in direct energy savings; covers 90% of plant billable energy demand
• Strategic Expansion: Initial four-unit installation commissioned in 2019, followed by a repeat order for two additional microturbines in 2020 to support facility expansion


The Challenge
For nearly 60 years, Regency Plastics has operated as one of North America's largest extruders and converters of polyethylene sheeting and packaging, operating its Toronto, Ontario facility 24 hours a day, 5 days a week. Operating in an electricity market with some of the highest utility power rates in the province, the manufacturer faced severe cost pressures that threatened stable production budgeting. Furthermore, the plant needed increased electrical capacity to support new extrusion lines and future operational phases without incurring excessive utility grid connection fees.


The Solution
Regency Plastics turned to a 390 kW on-site microturbine generation system managed with controls, expanding its fleet to six Capstone C65 low-pressure natural gas microturbines to power day-to-day manufacturing operations.
• 90% Energy Bill Offset: Generates over 2,000 MWh of clean electricity annually on-site, supplying 90% of the facility's total billable energy demand behind the meter.
• Favorable Power-Only Economics: Demonstrates that in high-rate utility markets like Ontario, microturbines deliver exceptional ROI and rate control operating in power-only mode—even without thermal heat recovery integration.
• Expanded Plant Capacity: Increases available on-site electrical capacity to support the addition of new plastic extrusion and converting lines without grid dependency.
• Modular Repeat Deployment: Started with four C65 units in 2019 and seamlessly expanded with two additional units in 2020 due to proven reliability and cost reduction.



The Results
• $300,000 Annual Savings: Significantly lowers manufacturing overhead, providing predictable, fixed energy costs that ensure stable product pricing.
• Insulated from Utility Rate Spikes: Safeguards plant operations against regional grid tariff increases with clean, self-generated baseload power.
• Uninterrupted 24/5 Production: Powers high-demand continuous industrial manufacturing across five weekly 24-hour operational shifts.
• Flexible Modular Growth: Leverages modular bay architecture to scale on-site power infrastructure in direct lockstep with business growth.