Motor Rewinding vs. Replacement:
How to Make the Right Call
When an electric motor fails, every plant manager faces the same urgent question:
Should we rewind it—or replace it?
Both options can get your operation back online, but the differences in cost, downtime, sustainability, and long-term performance can very significantly. At Troy Industrial Solutions, we’ve serviced thousands of motors across the Northeast with our motor rewinding services—so we can help you decide if rewinding makes sense for your situation and when replacement is the better move.
This guide will help you understand:
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What motor rewinding is
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The motor rewinding process
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Benefits of rewinding and remanufacturing
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When replacement is the smarter choice
What Is Motor Rewinding?
Motor rewinding is a specialized electric motor repair service that restores performance by replacing worn or damaged windings—the copper or aluminum coils are responsible for generating the magnetic fields that power the motor.
Over time, windings can degrade due to heat, vibration, electrical faults, and/or contamination, leading to efficiency loss or failure.
At Troy Industrial Solutions, our industrial motor repair technicians—with over 90 years of combined rewinding experience—perform rewinds in a controlled environment using advanced diagnostics, in-house engineering, and turnkey capabilities. Whether it’s a motor rebuild, redesign, or root-cause failure analysis, we extend motor life and optimize performance.
The Motor Rewinding Process
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Inspection & Disassembly – Open for access and assess motor condition
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Remove Old Windings – Carefully extract damaged windings and insulation material from the stator.
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Cleaning – Thoroughly clean and test the stator core and prep for new windings.
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Rewinding – Install new coils to precise manufacturer or custom specifications.
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Reassembly & Testing – Rebuild and rigorously test
When Motor Rewinding Is Ideal
Motor rewinding services are best when:
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The motor frame, core, and shaft are in good condition
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Quick turnaround is critical to avoid costly downtime
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The motor is custom, legacy, or difficult to replace
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You want to lower capital expenses
Our electric motor repair services include:
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Insulation and core testing
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Precision coil rewinding
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Dynamic balancing
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Final performance testing
Benefits of Motor Rewinding & Remanufacturing
1. Cost Savings
Rewinding can save up to 50% compared to buying a new motor—especially for large or specialized units.
2. Performance Restoration
Restores motors to near-original efficiency, sometimes improving performance.
3. Fast Turnaround
Often faster than waiting weeks for a replacement—especially custom motors.
4. Material Conservation
Keeps over 99% of copper, steel, and other components in service.
5. Lower Carbon Emissions
Cuts CO₂ output by 27%–65% compared to new manufacturing.
6. Energy Efficiency
Minimal efficiency loss (<0.2%)—sometimes improved with upgraded windings.
7. Supports the Circular Economy
Extends equipment life, reduces waste, and conserves resources.
8. Customization
Tailor windings for specific voltage, current, or speed needs.
When to Replace a Motor Instead
Sometimes replacement is the more cost-effective choice:
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Extensive mechanical damage beyond the windings
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Low-cost, off-the-shelf motors
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Need for higher efficiency or new technology
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Undersized or outdated motors
Troy Industrial Solutions stocks high-performance motors from top manufacturers to minimize downtime when replacement is the best move.
The Skills That Make the Difference in Motor Rewinding
Motor rewinding is a blend of science and craftsmanship:
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Reading and interpreting motor schematics
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Winding layout and coil configuration
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Core loss and insulation resistance testing
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Operating bake ovens, VPI (vacuum pressure impregnation) systems, and surge testers
Our factory-trained technicians handle AC and DC motors up to several thousand horsepower, including vertical turbine pumps and explosion-proof designs.
Why Choose Troy Industrial Solutions for Motor Rewinding Services?
With 163+ years of industrial service in the Northeast, Troy Industrial Solutions is the trusted partner for:
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24/7 emergency motor repair services
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Advanced diagnostics and root-cause analysis
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Laser alignment and dynamic balancing
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Field service and preventative maintenance
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Pick-up and delivery across New England and New York
Final Thoughts: Rewind or Replace?
Motor rewinding—done by experts—is often the smart, sustainable choice for extending motor life while reducing costs and environmental impact. But every case is unique.
At Troy Industrial Solutions, we inspect every motor before making a recommendation—whether it’s rewinding, replacement, or preventative maintenance.
Need your motor evaluated? Contact Us or visit TroyIndustrialSolutions.com to request service today.
