Rolls-Royce North America is expanding an engine plant in Aiken S.C., to increase machining capabilities for mtu Series 4000 components, to manufacture those parts domestically and decrease the volume of imports for those diesel and natural-gas engines. The $75-million project will be conducted in two phases, starting in Q1 2026. It’s expected to create 60 new jobs, according to Rolls-Royce.
The first phase will add 37,000 sq.ft. of manufacturing space. A further 22,000 sq.ft. would be added in the next phase, for a total expansion of 60,000 sq.ft. Rolls-Royce did not indicate the schedule for the second phase of expansion.
The project is part of a broader program by Rolls-Royce to serve the industrial and power sectors’ expanding data-center operations, which are increasing demand on electric grids. In June Rolls-Royce announced a $24-million expansion at its Power Systems division plant in Mankato, Minn., to increase production of high-power mtu gas generator sets by estimated 25%. That project is anticipated to add 100 jobs.
The mtu Series 4000 engines manufactured in South Carolina are used for power generation, locomotives, luxury yachts, and heavy-duty vehicles. The Series covers a power range, from 720 to 4,300 kW, depending on the number of cylinders, and the engines are configurable for diesel fuel, natural gas, and natural gas-hydrogen blends.
Engines built at Aiken, S.C., are assembled into complete generator sets at Mankato, Minn.
Currently, most of the components for the engines are machined in Germany and shipped to the U.S. as finished goods, according to Rolls-Royce. To meet the growing demand, more machining capacity in the U.S. is necessary, it added.
The Aiken plant was launched in 2010 and currently occupies 395,000 sq. ft., with production capabilities, an engine testing operation, office space, a research and development center, four large engine test stands, and a remanufacturing and overhaul center.
“The increased investment strengthens our ability to serve our U.S. customers,” according to Adam Wood, managing director for Rolls-Royce’s Power Systems division in America, “especially in the fast-growing American data center industry. By increasing our machining capabilities in Aiken, we can supply more engines to Mankato, enabling us to deliver more gensets with shorter lead times.”
