The conversation around transformer manufacturing has changed significantly over the past few years. 

While demand continues to rise, manufacturers are balancing long order books with material shortages, skilled labour constraints and increasing pressure to deliver equipment faster than ever before. Utilities are expanding networks to support renewable energy, electrified transport, industrial growth and rising electricity consumption, all while managing ageing infrastructure that still plays a vital role in maintaining reliable power systems. 

Against this backdrop, remanufacturing is becoming more than a maintenance activity. 

It is emerging as a strategic capability that allows manufacturers, utilities and service providers to improve supply chain resilience, maximise the value of existing assets and make better use of increasingly valuable raw materials. 

As the industry looks for practical ways to increase capacity without compromising reliability, circular thinking is becoming an important part of the conversation. 

A changing view of asset value 

Historically, transformers have often been viewed in relatively simple terms. 

Equipment was commissioned, maintained throughout its operational life and eventually replaced when it reached the end of its service life or experienced a significant failure. 

Today, that approach is evolving. 

Modern asset management recognises that many transformers retain significant technical value long before replacement becomes necessary. Advances in diagnostics, testing and engineering have made it possible to assess individual components in far greater detail, allowing refurbishment or remanufacturing to extend operational life while maintaining reliability. 

Rather than viewing ageing assets as liabilities, many organisations now see them as opportunities. 

The question is no longer simply, "How old is this transformer?" 

Instead, it is, "How much value can this asset continue to deliver?" 

Material security is becoming a business priority 

Transformer manufacturing depends on specialist materials that remain under significant pressure. 

Electrical steel, copper, insulation materials and specialist components all play a critical role in production, and many continue to experience supply constraints or price volatility. 

Remanufacturing helps reduce pressure on these supply chains by recovering value from existing assets wherever technically appropriate. 

Core components, structural elements and selected materials can often continue delivering reliable performance following refurbishment, reducing the demand for entirely new resources while supporting more efficient manufacturing. 

This approach is not about compromising quality. 

It is about making better use of proven engineering assets while maintaining the performance standards expected by utilities and network operators. 

As global demand for transformers continues to increase, efficient use of materials will become an increasingly important competitive advantage. 

Circularity supports supply chain resilience 

The benefits of remanufacturing extend well beyond sustainability. 

One of its greatest strengths is its ability to improve supply chain resilience. 

When new transformer lead times extend beyond project requirements, refurbishment can provide utilities with additional flexibility. 

Rather than waiting for replacement equipment, operators may be able to extend the service life of existing assets through targeted engineering interventions. 

Tra gli esempi figurano: 

• Replacing ageing insulation systems 

• Rifacimento dei commutatori 

• Upgrading cooling equipment 

• Installing modern monitoring systems 

• Replacing bushings and auxiliary components 

These projects can reduce delivery risk while supporting planned network expansion and improving asset reliability. 

For manufacturers and specialist service providers, remanufacturing also creates opportunities to maintain customer support throughout the entire lifecycle of the asset rather than only during initial production. 

Sustainability is becoming measurable 

Environmental performance is increasingly influencing procurement decisions across the power sector. 

Utilities are looking beyond equipment specifications to understand the wider environmental impact of the products they purchase, including manufacturing processes, material use and lifecycle performance. 

Remanufacturing contributes to these objectives by extending the productive life of existing assets and reducing the demand for new raw materials where technically appropriate. 

It also supports broader circular economy principles by encouraging reuse, refurbishment and responsible management of valuable engineering resources. 

Importantly, circularity should not be viewed solely through an environmental lens. 

For many organisations, it is equally about operational efficiency, cost management and long-term resilience. 

The strongest circular strategies deliver commercial value alongside environmental benefits. 

Engineering expertise remains central 

Successful remanufacturing is never simply a matter of replacing components. 

Every transformer has experienced different operating conditions, maintenance histories and loading profiles throughout its service life. 

Determining whether refurbishment is technically appropriate requires detailed engineering assessment supported by advanced diagnostics and experienced specialists. 

Digital condition monitoring, dissolved gas analysis, insulation testing and thermal assessment all contribute valuable information, but engineering judgement remains essential. 

The objective is not to maximise refurbishment at all costs. 

It is to identify the most appropriate technical solution for each individual asset. 

Sometimes that will mean remanufacturing. 

Sometimes it will mean replacement. 

The value lies in making informed decisions rather than following predetermined maintenance schedules. 

Manufacturers have an opportunity to expand their role 

Remanufacturing also presents opportunities for transformer manufacturers themselves. 

Rather than focusing exclusively on new production, manufacturers can strengthen customer relationships by supporting the complete asset lifecycle. 

Lifecycle services may include: 

• Asset condition assessments 

• Engineering consultancy 

• Refurbishment programmes 

• Component upgrades 

• Digital monitoring integration 

• Long-term maintenance planning 

These capabilities create stronger partnerships with utilities while providing customers with greater flexibility when managing ageing infrastructure. 

As electricity networks continue expanding, manufacturers that support both new production and lifecycle optimisation are likely to become increasingly valuable strategic partners. 

Collaboration will drive the circular economy 

Building a more circular transformer industry requires collaboration across the value chain. 

Utilities provide operational insight into asset performance. 

Manufacturers contribute design expertise and engineering knowledge. 

Specialist repair organisations deliver refurbishment capabilities. 

Component suppliers continue developing materials and technologies that improve both new production and remanufacturing. 

Digital technology providers enhance diagnostics, monitoring and lifecycle management. 

Together, these organisations create an ecosystem capable of extracting greater value from existing infrastructure while continuing to support new manufacturing where it is needed most. 

No single organisation can achieve this transition independently. 

Uno sguardo al futuro 

Demand for transformers is expected to remain strong as electricity networks continue to expand and modernise. 

Meeting that demand will require continued investment in manufacturing capacity, automation, skilled engineering and stronger supply chains. 

It will also require the industry to think differently about the assets already in service. 

Remanufacturing is no longer simply about extending equipment life. 

It is becoming an important strategy for improving material efficiency, strengthening supply chain resilience and helping utilities deliver infrastructure projects with greater confidence. 

CWIEME Berlin provides a platform where these conversations can take place across the entire value chain. By bringing together transformer manufacturers, utilities, component suppliers, machinery providers, repair specialists and technology companies, the event enables the industry to explore practical approaches to lifecycle management, material efficiency and the future of transformer manufacturing. 

Building a circular transformer industry is not about replacing new manufacturing. 

It is about complementing it. 

By combining engineering expertise, advanced diagnostics and closer collaboration, the industry has an opportunity to deliver more resilient supply chains, maximise valuable resources and build electricity networks that are fit for the decades ahead.