Hydraulic Institute Evaluates Cost-Benefit of Motor Rewinding vs. Replacement in Mining Operations

When two critical motors—rated at 18.5 kW (25 hp) and 90 kW (120 hp)—burned out, the maintenance team faced a common decision: rewind or replace. While rewinding is often less expensive upfront, it can result in reduced efficiency. This Hydraulic Institute case study presents a comparative cost analysis, revealing that motor replacement offers greater long-term value, with a break-even point reached within two years.

Intended Audience: Mining Engineers, Maintenance Managers, Electrical Supervisors

Objective: To determine whether rewinding or replacing failed motors is more cost-effective over the operational lifecycle, considering energy efficiency and total cost of ownership.

Description of System: The 18.5 kW and 90 kW motors in question were integral to a mining facility’s operations. Both had failed and were candidates for either rewinding or replacement with modern, high-efficiency models.  

Description of Intervention: Industry surveys indicate that rewound motors typically operate at 1–2 percent lower efficiency than their original specifications. Using manufacturer-provided efficiency data for new motors and estimated post-rewind performance, a detailed cost analysis was conducted. The results, summarized in Table 1, form the basis for the decision-making process.

To learn more, visit pumps.org/2026/01/04/evaluating-the-cost-benefit-of-motor-rewinding-vs-replacement-in-mining-operations