Rock Run Industries

At a Glance
• System Configuration: C400S + C200S Dual Mode Capstone Microturbines (600 kW total across 3 × 200 kW modular bays) integrated with a 2 MWh BESS and 1 MW Solar PV Field
• Annual Generation: >2,000 MWh/year of resilient, high-efficiency power
• Thermal Process Recovery: Microturbine waste exhaust heat is ducted directly into industrial powder-coating curing ovens
• Financial Impact: ~$100,000 / year in direct energy cost savings


The Challenge
Rock Run Industries operates a 300,000-square-foot contract manufacturing facility in Topeka, Indiana, specializing in laser cutting, welding, and powder coating for the RV, outdoor leisure, and steel service industries. Heavy manufacturing processes—especially high-precision lasers and curing ovens—require steady, high-quality power. Legacy diesel generator solutions created power quality incompatibilities with modern inverter-based equipment, while utility grid interruptions threatened production schedules. To protect operations, lower natural gas consumption, and advance sustainability goals, Rock Run needed a clean, resilient, and fully harmonized distributed energy resource (DER) microgrid.


The Solution
An advanced, multi-asset industrial microgrid was deployed, using 600 kW of modular Capstone microturbines as the core dispatchable power generation asset paired with solar energy and battery storage.
• Multi-Asset DER Harmonization: Combines 600 kW of microturbines, a 1 MW solar field, and a 2 MWh battery energy storage system (BESS). Intelligent microgrid controls prioritize zero-emission solar energy first, deploying microturbine power dynamically only when required by site load.
• Direct Process Heat Recovery: Captures high-grade microturbine exhaust heat and ducts it directly into curing ovens within the powder-coating line, significantly reducing facility natural gas purchases.
• Dual-Mode Microgrid Resiliency: Replaced incompatible diesel generation with an inverter-based microturbine architecture capable of operating in tandem with the utility grid or seamlessly islanding during local outages.
• Modular 200 kW Staged Power: Utilizes three 200 kW turbine bays that stage up or down in real time to match exact facility load demands, ensuring optimal fuel efficiency and low emissions.


The Results
• 99% System Uptime: Guarantees reliable, uninterrupted power for sensitive, high-demand manufacturing operations like laser cutting and welding.
• $100,000 Annual Savings: Reduces utility electricity and process natural gas costs by $100,000 per year.
• Maximized Environmental Benefits: Minimizes natural gas fuel consumption and greenhouse gas (GHG) emissions through automated solar prioritization and waste heat reuse.
• Low-Maintenance Industrial Reliability: Features air-bearing turbine technology with only three moving parts across the 600 kW array, eliminating oil, liquid coolants, and frequent engine overhauls.