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Not every failed motor is worth rewinding. Use the rule of thumb, then the numbers, then the efficiency math — because a modern premium motor often pays for itself in under two years.
If the cost to repair exceeds 65% of the price of a new premium-efficiency motor, replace it.
• Motor is over 100 HP and mission-critical.
• It’s a custom or hard-to-source unit (special voltage, mount, or shaft).
• The motor is less than 5 years old and already premium efficient.
• Repair quote is under 50% of a new equivalent’s price.
• Motor is under 50 HP and standard NEMA frame.
• It’s older than 15 years (efficiency has advanced significantly).
• Repair quote exceeds 65% of a new premium-efficiency equivalent.
• It’s failed on the same fault before — underlying issue won’t go away.
A 20 HP motor running 3-shift can spend more on electricity in one year than the motor cost. Modern premium-efficiency motors typically pay back the price difference in 18–24 months.
| HP | 1990s Standard (%) | Modern Premium Eff. (%) | Annual Savings* |
|---|---|---|---|
| 5 HP | 84.0% | 89.5% | ~$180 |
| 10 HP | 86.0% | 91.7% | ~$350 |
| 20 HP | 88.0% | 93.0% | ~$650 |
| 50 HP | 90.5% | 94.5% | ~$1,400 |
| 100 HP | 92.0% | 95.4% | ~$2,800 |
*Estimated at $0.12/kWh, 6,000 hours/year, 75% load. Use our motor efficiency calculator for your exact numbers.
We’ll price a modern replacement side-by-side with your repair quote — you decide, no pressure.
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