Visiting our Bhosari works
What customers see on a plant visit, from stamping to the test bench, and how to arrange one.
What a motor rewind costs, and why
Copper, labour, bearings and testing: how we price a rewind, with typical figures for common ratings.
When a motor burns out, the rewind quote is often the first number a maintenance team needs. Here is how we build it, so the figure makes sense.
Copper is the largest part. A rewind replaces all the winding wire, and its weight rises with the motor’s size. A 7.5 kW 4-pole motor uses roughly 6 to 7 kg of enamelled copper wire; a 37 kW motor around 25 to 30 kg. With copper prices where they are, wire is 40 to 50% of most quotes, and when copper moves, our quotes move with it. Labour is next. Stripping, winding, connecting and lacing a 7.5 kW motor takes about a day and a half for one winder; a 37 kW motor takes two winders three days. Then come slot insulation and varnish, the oven bake, new bearings, which we always fit on a rewind, and testing.
As a guide at today’s prices, a 7.5 kW, 4-pole TEFC motor costs ₹9,500 to ₹11,500 to rewind with new bearings, and a 37 kW about ₹42,000 to ₹48,000. Shaft repairs, a damaged core or a new fan cover are quoted separately, with photos.
Compare this with a new motor. Below about 5.5 kW, a new IE3 motor often costs little more than a rewind and uses less power, so we usually suggest replacing. Above 30 kW, a careful rewind that keeps the original winding data is usually good value. Every rewind carries our six-month warranty and goes out with its test sheet.
