Electric motors and generators are built to last, but over years of service, insulation weakens, windings deteriorate, and performance begins to drop. When that happens, businesses are often faced with a decision, replace the unit entirely or restore it through a professional rewind.

A rewind, when carried out correctly and to OEM or industry standards, can return critical equipment to reliable, efficient operation at a fraction of the replacement cost. Here’s why rewinding is not only a viable option, but often the most strategic one for industrial sites, plants, and commercial operations.

Restores equipment to original performance levels
A properly executed rewind renews the condition of the motor or generator’s windings, the electrical heart of the machine. New insulation, refurbished coils, and precise reassembly restore the machine’s original electrical characteristics:

correct resistance and impedance
balanced phases
proper insulation integrity
stable running temperatures

For many assets, this means performance that is not only as good as new, but sometimes even better than when the machine first entered service.

Extends the life of your existing assets
Motors and generators are long-life assets. Their mechanical components, frames, rotors, stators, and shafts, often remain in excellent condition even after decades of use.

A rewind gives these components a second lifespan by replacing only the worn electrical parts. This approach helps businesses avoid unnecessary capital expenditure and squeeze significantly more value from well-built machines.

For heavy-duty or hard-to-replace equipment, rewinding can add many years of dependable operation.

More cost-effective than full replacement
Replacing a motor or generator involves more than just the purchase price. There are also:

installation costs
downtime during changeout
reconfiguring mounting or couplings
potential changes to electrical systems
delays sourcing specialty units

Rewinding is typically far more economical, often 30–60% less than buying a new machine, depending on size and specifications. For large industrial motors, the savings can be substantial.

Faster turnaround and reduced downtime
Lead times for new motors and generators can be long, especially for custom or high-horsepower units. Manufacturing delays and shipping times can extend downtime far beyond what’s acceptable for critical plant operations.

A rewind, performed by an experienced service provider like TRS, can dramatically shorten that outage window. Many rewinds can be completed quickly and scheduled around shutdowns or repair windows, helping keep operations on track.

Improves efficiency when done to the right standard
Modern materials and insulation systems are more advanced than those used decades ago. When old windings are replaced with higher-quality varnishes, insulation, and copper:

electrical losses can be lower
heat dissipation is improved
the motor runs closer to design efficiency

This means that a quality rewind doesn’t degrade efficiency, it protects it. When performed correctly, a rewind upholds the original efficiency rating of the equipment, aligning with industry-standard practices and proven test procedures.

Reduces the risk of catastrophic failure
Failing insulation and winding damage are two of the most common causes of motor and generator breakdowns. These failures often occur at the worst time, during periods of peak load or when equipment is already under stress.

A rewind eliminates the underlying electrical deterioration, making the unit safer and far less prone to sudden failure. By renewing the electrical system, you restore reliability where it matters most.

Supports sustainability and waste reduction
Rewinding extends the usable life of existing machinery, which dramatically reduces waste. Instead of scrapping a motor or generator, often hundreds of kilograms of metal, rewinding reuses the majority of the component while replacing only what’s necessary.

For organisations with sustainability goals or environmental compliance requirements, rewinding is a responsible choice that reduces both resource consumption and landfill impact.

Why TRS for rewinds?
At TRS, we specialise in rewinds for motors and generators of all sizes, from small industrial motors to large critical-service equipment. Our team follows rigorous procedures, using high-quality materials and precision testing at every stage.

When you work with TRS, you get:

expert rewind workmanship that protects performance and efficiency
advanced insulation systems for long-term reliability
thorough mechanical and electrical inspections
high-temperature varnish curing for maximum durability
complete reporting and post-rewind verification

Our focus is always on keeping your assets running reliably, efficiently, and safely.

Talk to TRS about your motor or generator rewind
If your equipment is showing signs of deterioration, underperforming, or due for refurbishment, our team is here to help. We can assess your unit, recommend the best course of action, and carry out a high-quality rewind that restores long-term reliability.

Get in touch with TRS today to discuss your rewind needs or book an inspection with our specialist team.

Summary
Generator and motor rewinds offer businesses a cost-effective alternative to full replacement, restoring equipment performance, extending its lifespan, and reducing the risk of unexpected failures. With faster turnaround times, improved reliability, and sustainability benefits, rewinds are often the smartest option for industrial and commercial operations. When performed to a high standard, a rewind maintains original efficiency and delivers years of additional service.

TRS provides professional, high-quality rewind services designed to maximise equipment life and support long-term plant reliability.