Raising motor rewinding standards to reduce energy waste and emissions in India

By Staff Report March 3, 2025 6:44 pm IST

The International Copper Association India (ICA India) has partnered with the Bureau of Energy Efficiency (BEE) and the Confederation of Indian Industry (CII) to launch the Motor Rewinder Certification System. This initiative aims to standardize motor rewinding practices, enhancing technician skills, promoting high-quality materials, and enforcing standardised testing and documentation processes.

The improper rewinding of electric motors in India has emerged as a significant issue, leading to decreased motor efficiency, increased energy consumption, and higher carbon emissions. With limited training, inconsistent quality control, and a lack of regulatory oversight, the sector urgently needs reform to align with India’s energy and sustainability goals.

Motor failures in India often arise from mechanical and electrical issues, compounded by poor working conditions. Mechanical stresses such as vibration transfer, frequent start-stop cycles, and overloading, along with electrical issues like voltage imbalances and single phasing, are common causes of motor breakdowns. Harsh environmental conditions, including excessive dust and high temperatures, further accelerate wear and tear, reducing the lifespan of motors.

A major contributor to this inefficiency is the widespread reliance on unauthorised service centres, which use outdated rewinding techniques. Many of these centres employ methods such as thinner copper wires and manual winding without proper testing capabilities, leading to a significant loss in motor efficiency. Studies indicate that each rewinding process results in an average efficiency decline of 1.03%, making motors less reliable and more energy intensive. Yet, due to their proximity to industrial areas and established trust with end users, these unauthorised centres continue to dominate the market. While authorised centres are preferred for motors covered under warranty, the tendency to choose experienced unauthorised rewinders for higher-capacity motors remains prevalent.

Recognising the urgency of reform, the International Copper Association India (ICA India) has partnered with the Bureau of Energy Efficiency (BEE) and the Confederation of Indian Industry (CII) to launch the Motor Rewinder Certification System. This initiative is designed to standardise motor rewinding practices, ensuring that motors retain their efficiency even after repairs. By implementing clear benchmarks, the initiative focuses on enhancing technician skills, promoting the use of high-quality materials, and enforcing standardised testing and documentation processes. With its structured approach, the program has the potential to curb electricity wastage, reduce carbon emissions, and strengthen the overall competitiveness of India’s motor rewinding industry.

A key aspect of this initiative is its potential to improve skill development and expand the capabilities of motor rewinding centres across the country. The Bureau of Energy Efficiency’s pilot project in Haryana exemplifies how state-level adoption can create a strong foundation for nationwide implementation. By streamlining rewinding standards, India can pioneer energy-efficient motor maintenance with minimal investment while advancing its broader climate and economic objectives.

Authorised rewinders adhere to strict procedures, including the use of proper tools, adherence to OEM guidelines, and maintaining consistent wire gauges. The Motor Rewinder Certification System enhances these practices by equipping technicians with the necessary skills to perform rewinding accurately, ensuring motors continue to operate at their original design and performance levels.

The benefits of efficient rewinding practices extend far beyond individual industries. If adopted for all low-tension induction motors, agricultural pumps, and housing fans, India could save an estimated 33.18 billion units of energy annually, leading to a reduction of 29.87 million tons in greenhouse gas emissions. These figures underscore the transformative potential of efficient motor rewinding in aligning industrial operations with India’s broader sustainability and economic goals.

In addition to improving reliability, stability, and productivity, best rewinding practices will also help preserve the performance and longevity of electric motors. Moving forward, strong collaboration between industries, manufacturers, rewinders, and regulatory bodies is essential to drive widespread adoption of these efficiency measures. Through greater awareness, structured training programs, and strict adherence to high standards, India can establish a global benchmark for sustainable motor maintenance practices, unlocking long-term economic and environmental benefits.