If you’ve tried to order electrical equipment in the last few years, you know how long it can take to get what you need. Electrical contractors, utilities and project managers face lead times stretching out months to even years.

Many companies have experienced serious delays in getting new transformers. Sometimes it takes weeks even to receive a quote for a new transformer. Actually getting the transformer is another story.

Unsurprisingly, many companies are now reconsidering how they source transformers.

Enter reconditioning.

The importance of reconditioning transformers

Here at Maddox, we’re big believers in recycling used and surplus transformers. The industry term for this is remanufacturing or reconditioning. Reconditioning is a “comprehensive and rigorous industrial process by which a previously sold, leased, used, worn or nonfunctional product or part is returned to a ‘like-new’ or ‘better-than-new’ condition, from both a quality and performance perspective, through a controlled, reproducible and sustainable process.”

The United States is full of this kind of old infrastructure and industrial equipment like transformers. In previous years, it was cost-effective enough to just remove the old equipment and buy new stuff. But those days are gone. Instead, we should turn our attention to reconditioning all those old or out-of-use transformers.

The benefits of transformer reconditioning

The benefits of reconditioning transformers are numerous. Consider a few of the following:

Speed

It’s quicker to recondition transformers than to build new ones. Want to beat supply chain delays? Buy reconditioned. While lead times on new, factory-built transformers are stretching out to more than 80 weeks, in-stock, reconditioned transformers can be made available as quickly as 1 to 4 weeks.

Availability

Reconditioning old transformers increases the available stock of transformers that are ready to be deployed on the market. Moreover, purchasing reconditioned transformers relieves some of the stress on the supply chain. While recycling an electrically healthy transformer increases the availability of recycled materials for new products, it also increases the demand for the same product taken out of service, which now must be replaced. This cyclical manufacturing process can’t keep up with current industry demand. Utilizing reconditioned transformers reduces the overall product demand, which in turn brings relief to factories for the manufacture of new units.

Cost savings

By increasing the supply of transformers, reconditioning helps drive down the prices. Reconditioned transformers also cost less to fix and repair than to build a brand-new unit. In contrast to the inflated cost of new, factory-built units, reconditioned transformers offer a cost reduction between 10% and 40% for the same transformer.

Environmental impact

The negative environmental impact of reconditioning is far lower than building a new transformer. Reconditioned transformers lower the high energy consumption and greenhouse gas emissions associated with new material manufacturing.

Reliability

According to a study done by the Hartford Steam Boiler Inspection & Insurance Co., the second leading cause of transformer failure stems from design and manufacturing issues. Many such failures occur at initial energization. Purchasing a reconditioned unit, one with a proven track record in the field, provides an additional level of assurance for future reliability. In the same vein, the reconditioning process includes identifying any previous design flaws and correcting any defects for longer service life. The warranty period for reconditioned transformers is also often longer than new factory-built units.

Reconditioning transformers at Maddox

Many utilities, small corporations and municipalities don’t find it cost-effective to repair and recondition their own transformers, so Maddox offers a complete solution for transformer refurbishment and repairs. Companies can buy reconditioned transformers like padmounts, substations, dry-types and polemounts directly from Maddox, or send their older transformers to Maddox for repair, resulting in shorter lead times and a more efficient supply chain.

A Maddox transformer technician reconditioning a padmount transformer.

Maddox buys surplus transformers to recondition

In addition to repairs, Maddox also buys old surplus transformers from companies that no longer need or want them. Electrical contractors, utilities or recyclers who are looking to get rid of their old units can sell their surplus transformers to Maddox for three to five times the scrap value. Maddox puts these transformers through an extensive reconditioning and transformer testing process before they’re redeployed back into the supply chain. While new transformer manufacturing lead times in the United States stand between 60 and 80 weeks, depending on market conditions, Maddox’s transformer reconditioning lead times stand between 1 and 4 weeks.

Every time we can find and rebuild an old transformer, it means a project gets online that much quicker. That’s good for our workers, our economy, the global supply chain and even the environment—everybody wins. We offer the best value for any new and used transformers, and we’ll even take care of all the logistics. You can sit back, relax and know that you’re helping our nation keep the power on.

If you or anyone you know have old units sitting unused, we’d love to buy your surplus transformers.