Precision motor winding ensures the proper alignment and functionality of coils, reducing energy losses, overheating, and mechanical failure. For industrial applications, such as those serviced by Australian Winders, precision winding directly improves operational performance and extends motor lifespan, reducing downtime and costly repairs.
Learn more about the impact of precision motor winding on operational performance in our detailed blog post.
Australian Winders offers customised motor winding solutions tailored to the specific requirements of your equipment. This approach optimises motor performance, ensuring maximum efficiency in applications like mining, power generation, and heavy industry.
Find out how we optimise motor performance through custom winding in this article.
Precision motor winding reduces heat and friction within the motor, leading to greater energy efficiency. This lowers operational costs and improves the overall sustainability of industrial operations, a key benefit offered by Australian Winders.
Explore more on how precision winding contributes to energy efficiency in our blog.
Motor winding improves energy efficiency by optimising the magnetic fields within motors, reducing heat buildup and energy loss. At Australian Winders, our precision winding techniques enhance motor performance, reducing energy consumption and lowering operational costs.
Discover how motor winding can help your business improve energy efficiency in our full article.
Sustainability in motor winding involves reducing waste and extending the life of industrial motors. Australian Winders achieves this by refurbishing motors with high-quality winding solutions that maximise efficiency, reducing the need for new equipment and lowering carbon footprints.
Learn how our motor winding solutions support sustainability goals in this blog post.
Advanced materials like improved insulators and copper alloys reduce resistance and heat generation in motor windings. Australian Winders utilises these materials to ensure motors run more efficiently, lowering both energy use and maintenance costs.
Read more about how advanced materials contribute to energy efficiency in motor winding in this article.
Australian Winders adheres to stringent international safety standards, including those set by the IEC and ISO. Our technicians undergo continuous training to ensure compliance in motor winding, ensuring both performance and safety across industrial applications.
Find out more about our commitment to compliance and safety in this blog post.
Compliance ensures that motor winding services meet safety regulations and operational standards, particularly in high-risk industries like mining and power generation. Australian Winders guarantees that all motor windings are completed to meet or exceed global safety standards.
Learn about the importance of compliance in motor winding and how we ensure safety in this article.
Australian Winders applies rigorous quality control procedures, including thorough testing and inspections, to ensure all motor windings meet performance and safety benchmarks. These procedures are vital for ensuring motor longevity and operational reliability.
Learn about our stringent quality control measures in motor winding in this blog.
Great question, and one we get often. If you’re seeing signs like insulation degradation, partial discharge activity, or reduced power output, it’s likely you’re heading toward a rewind. That said, our first step is always diagnosis. We’ll assess whether repair is still viable or if a full rewind is the most reliable path forward.
Timelines depend on the asset, but for context, our Toshiba 660–720MW upgrade rewinds were completed within six weeks. We fully remove and replace the stator windings using precision bar seating, ripple spring tech, epoxy moulding, and full HV, ELCID and PD testing. Every step is built around maximising operational life.
Our teams aren’t just sparkies, they’re industrial rewind specialists. Most of them have decades of field experience in high-voltage environments and understand the nuance of critical infrastructure. That’s why clients like Siemens and Pacific Blue call on us when the job is too specialised for anyone else.
Yes. We manufacture our own coils, bars, and winding kits in-house, so we’re not bound to off-the-shelf specs. That gives us the flexibility to match original designs or engineer something better, based on performance and longevity requirements.
Start with the numbers. A rewind typically costs less than asset replacement and adds decades to your equipment’s operational life. We also provide independent test results, QA/QC guarantees, and case studies to help you make the business case confidently.
We don’t just test at the end, we build it into every step. That includes insulation resistance, surge testing, HV testing, ELCID, partial discharge analysis and more. Our results regularly exceed standards (think 100Pc vs 400Pc thresholds), so you’re never left guessing about quality.
Breakdowns often come down to avoidable issues such asa insulation failure, coil degradation, or undetected partial discharge activity. In most cases, these warning signs show up well before a major failure, which is why predictive diagnostics and routine inspections are so critical.
We move quickly because we know every minute counts during unplanned outages. Our field technicians are trained for rapid mobilisation and come equipped to perform diagnostics, repairs, and component replacement on-site, with safety and speed in equal measure.
Yes, regularly. We’ve completed major rewind projects in remote locations like Fiji and Alaska, dealing with everything from tropical weather to logistical delays and access restrictions. Our project management team is used to working around these kinds of constraints.
Reactive repairs cost more, take longer, and often result in downtime you could’ve avoided. Predictive maintenance uses tools like wedge testing, flux monitoring and partial discharge analysis to detect issues early, so you can plan ahead, not panic later.
We don’t cut corners. Testing includes surge and Hipot tests, ELCID core testing, partial discharge analysis, and full QA/QC inspection. This ensures equipment is safe, reliable, and restored to high performance standards before we leave site.
Our methods are refined by years of in-field work on some of the world’s most demanding assets. We do things properly, by hand, with precision, backed by independent testing and decades of experience. That’s why clients trust us with their critical infrastructure.
Start with compliance and traceability. A good supplier will provide full documentation, meet IEEE/IEC standards, and back every coil with independent testing. Beyond that, look for in-house expertise or manufacturers who actually understand your equipment, not just how to copy it.
It often comes down to traceability and consistency. Overseas suppliers might cut corners on materials or testing, which can lead to hidden faults. With Australian-made coils, you get full transparency, rigorous QA, and compliance with global IEEE and IEC standards.
Timelines depend on specs, but we’re known for rapid turnarounds. Because we manufacture in-house and manage the entire process end to end, we avoid common delays and keep your downtime to a minimum.
These coils require precise layering, curing, and testing to meet high-voltage performance standards. It’s not a job for generalists. Every step must be controlled and tested to ensure electrical integrity and long-term durability.
Yes. Whether you need an exact match or a performance upgrade, our team can reverse-engineer or custom-design coils to suit your asset. It’s part of what makes us specialists, not just manufacturers.
Every coil we manufacture undergoes a full suite of tests including insulation resistance, surge, and dimensional checks. We also verify material integrity and ensure each unit meets IEEE and IEC standards. Nothing leaves our facility without passing strict QA protocols that reflect the same standards we apply in the field.
Rail motors operate under constant stress, including vibration, thermal cycling, and exposure to contaminants like dust and moisture. These conditions accelerate insulation wear and increase the risk of breakdowns. If not maintained correctly, even small issues can trigger large-scale operational disruptions.
We focus on early intervention through advanced diagnostics and coil systems built for durability. Our field teams use proven methods that prevent issues before they escalate. The result is fewer failures, longer intervals between servicing, and more consistent fleet availability.
Yes, customisation is a core part of what we do. Our team can replicate original equipment or redesign coils to improve performance in legacy systems. We work closely with operators to meet exact specifications, even when the original documentation no longer exists.
We use high-performance insulation designed specifically for rail environments. These systems are built to resist dirt, heat, and mechanical stress, which protects the coils in harsh operating conditions. This significantly improves long-term reliability and performance.
Production times depend on the complexity and quantity required, but we are structured for speed. Our manufacturing is handled in-house by experienced technicians, which gives us greater control over delivery times. This helps reduce the overall downtime of your fleet.
Yes, every coil is manufactured to meet or exceed the relevant rail industry benchmarks, including IEEE and IEC standards. We also conduct independent testing throughout the process to ensure full compliance and reliability. Safety and quality are non-negotiable in every project.
Absolutely. Our field service teams provide rapid response support that includes fault diagnostics, system assessments, and precision repairs. We are equipped to get your assets back online quickly, safely, and with minimal disruption to your schedule.
We combine decades of hands-on expertise with a commitment to high-quality materials and in-depth testing. Most of our components are made by hand in controlled environments by skilled technicians. That level of care means better performance and a longer life for every coil we produce.