Set the Foundation for a Reliable Year

As you prepare your new year’s maintenance and capital budgets, one area that deserves extra attention is your electric motors. Motors power the systems that keep your facility running — from HVAC and pumps to production equipment. Yet too often, motor maintenance and replacement costs catch teams off guard.

At Dreisilker, we’ve spent decades helping facilities make smart, proactive decisions about their motors. Whether it’s repairing, replacing, or upgrading systems for better reliability, a clear budget and preventive plan will save you both downtime and dollars.

In this blog, we outline key considerations to help you plan next year’s budget with confidence.

Understanding the True Cost of a Motor

The price of a motor is only part of the story. When you factor in labor, downtime, and lost production, the total cost of ownership can multiply quickly. For example, a 25-HP motor might cost a few thousand dollars, but an unexpected failure could cost far more in lost output and emergency repairs.

As Plant Services notes, “The real question isn’t ‘what does a new motor cost?’ but ‘what does a failed motor cost you per hour of downtime?’” That perspective shifts budgeting from simple cost comparison to reliability planning.

That’s why smart budgeting considers not just replacement costs, but also:

• Scheduled maintenance and testing

• Spare inventory for critical equipment

• Condition monitoring services (vibration, infrared, or motor testing)

• Reliability considerations, such as shaft grounding rings or CoolBlue inductive absorbers

When you look at motors through this lens, budgeting becomes less about reacting to breakdowns and more about keeping your operations steady, predictable, and profitable all year long.

Evaluate Repair vs. Replace Scenarios

When motors fail, knowing when to repair versus replace is key to budgeting accuracy.

Industry guidance suggests that if the repair cost exceeds roughly 60% of the cost of a new, high-efficiency motor, replacement may make more financial sense.

• Repair is often best for large, custom, or legacy motors where replacement parts are costly or unavailable.

• Replace when the motor is small, standard, or older and less efficient.

At Dreisilker, our motor experts help customers analyze both sides — factoring in age, efficiency, reliability, and long-term operating costs. To learn more about how we help our customers decide, read our article: When Do You Repair or Replace Your Electric Motor?

Know When to Keep a Spare Motor on Hand

Keeping a spare isn’t always necessary, but for certain applications, it’s the difference between hours and days of lost production.

Here are a few guidelines to help you budget wisely:

• Consider a spare when the motor is critical to production, safety, or environmental control and has a long lead time for replacement.

• Consider a spare if the motor is custom, obsolete, or specialty-rated, making replacement parts difficult to source quickly.

• Rely on a replacement when the motor is a standard frame size that can be obtained within 24–48 hours.

• When you do have a spare on hand, ensure that they are stored properly — in a clean, climate-controlled area, with shafts rotated periodically and windings checked for insulation resistance before installation.

Planning ahead for spares might feel like an added cost, but it’s really budgeting for uptime — protecting your operations from the far greater cost of unplanned downtime. To learn more, read our blog: When to have a Spare Electric Motor

Budget for Preventive Maintenance Services

Unexpected failures can throw even the most careful budgets off track. That’s why the most reliable facilities build Preventive Maintenance (PM) plans into their annual budgets. These plans turn unpredictable repair costs into planned, budgeted activities — helping you detect problems early and avoid expensive downtime.

At Dreisilker, our PM programs are tailored to your equipment, schedule, and operational needs. Each partnership includes predictive technologies like infrared thermography and vibration analysis, along with detailed reports and trend data to support maintenance decisions.

Infrared Inspections

Infrared (IR) inspections use thermal imaging to identify heat patterns that point to hidden electrical or mechanical issues — such as loose connections, overloads, or failing bearings. By detecting these issues before they become failures, infrared analysis prevents unexpected shutdowns and improves safety.

Vibration Analysis

Vibration analysis measures the movement of motors and rotating equipment to catch early signs of imbalance, misalignment, looseness, or bearing wear. By trending data over time, our technicians can predict when components will need attention — allowing you to plan repairs during scheduled downtime instead of reacting to emergencies.

PM contracts not only make budgeting easier — they protect your investment and keep your motors performing at their best year after year.

Work With Your Motor Experts to Prevent Recurring Issues

Partnering with a trusted motor solutions provider should be part of your annual maintenance and capital plan. Building collaboration time into your budget ensures you’re not just fixing problems — you’re preventing them.

Preventive maintenance catches issues early, but only root-cause analysis stops them from happening again. By working with experts who understand both the electrical and mechanical sides of motor performance, you can uncover the true reasons behind failures — not just the symptoms.

At Dreisilker, our technicians and engineers work directly with customers to analyze failure patterns such as:

• Bearing failure in VFD applications, caused by induced shaft voltage and circulating currents

• Overheating or insulation breakdown due to poor ventilation or overloading

• Misalignment and imbalance leading to vibration and premature wear

• Contamination or moisture that damages windings and bearings

Through root-cause analysis, we identify the specific conditions that led to failure and recommend solutions to prevent them from happening again. In many cases, reliability upgrades — like installing CoolBlue inductive absorbers or shaft grounding rings — can significantly extend motor life in VFD-driven systems.

We realize this type of collaboration isn’t always a hard cost you can list in a budget. But it’s important to account for the soft costs — the time your team spends reviewing reports, discussing performance data, and planning improvements with us. That time investment pays dividends in fewer breakdowns, longer motor life, and a more predictable maintenance budget.

A trusted repair partner should do more than rebuild your motor — they should help you understand its environment, its stresses, and the steps you can take to make each repair stronger than the last. Working together on failure analysis and reliability improvements turns every repair into an opportunity for better performance and lower lifecycle costs.

The Bottom Line

Budgeting for electric motors isn’t just about numbers — it’s about reliability strategy. By planning for repairs, replacements, and proactive maintenance, you can reduce emergency expenses and keep your systems performing year-round.

“The only path to reducing reactive maintenance is to execute planned maintenance.” — Plant Services

Let’s work together to build yours.

Contact Dreisilker to review your 2026 maintenance and reliability plan.
We’ll help you estimate costs, prioritize upgrades, and schedule services that keep your motors running strong.

As summer temperatures climb, it’s not just people and buildings that feel the heat. Electric motors—both small HVAC and large industrial motors—can be vulnerable to high ambient temperatures. Understanding how extreme heat affects these motors can help you keep your systems running smoothly, reduce downtime, and save money on repairs.

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The Impact of Extreme Heat on Small HVAC Motors

Small motors in HVAC systems—like blower motors or condenser fan motors—often work in hot environments such as attics, rooftops, or tight mechanical rooms. Extreme heat can create these problems:

• Insulation Breakdown: High temperatures speed up insulation aging, leading to short circuits or winding failures. For electric motor insulation systems, every 10 °C rise above the rated temperature roughly halves insulation life (IEC/NEMA Rule).

• Thermal Overload: Small motors are typically sized close to their load. Hot weather pushes them over their limits, causing trips and failures.

• Lubrication Failures: Heat degrades grease and oil, causing bearings to wear faster or seize (ABB Motor Failure Guide).

• Decreased Efficiency: Electrical resistance rises with heat, meaning more energy loss and higher operating costs.

• Capacitor Failures: Many small HVAC motors rely on capacitors that are especially sensitive to heat.

  

Mitigation Tips:

Choose motors rated for higher ambient temperatures.
Ensure good airflow and ventilation.
Regularly clean dust and debris.
Check capacitors and bearings during routine maintenance.

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The Impact of Extreme Heat on Large Industrial Motors

For large industrial motors powering pumps, fans, compressors, or conveyors, extreme heat has even bigger impacts:

• Insulation and Windings: Elevated heat accelerates insulation breakdown, with repairs being more complex and expensive. The IEC/NEMA thermal life rule applies here, too.

• Higher Heat Load: Large motors generate more internal heat and rely heavily on effective cooling systems. High ambient temperatures reduce cooling fan or heat exchanger efficiency (WEG Motor Specification Guide).

• Derating Requirements: Motors often need to run below their nameplate rating when ambient temps rise to avoid overheating and failure.

• Bearing and Lubrication Stress: High temperatures break down lubricants faster, halving bearing and grease life for every 15 °C increase (ABB Guide).

• Rotor and Stator Expansion: Uneven heating can reduce critical clearances, risking contact, vibration, or damage (Windings High-Temperature Challenges).

• Electrical Losses: Increased temperatures raise copper resistance, resulting in higher I²R losses and reduced efficiency.

• Cooling System Stress: Air or water-cooled systems lose effectiveness in extreme heat.

• Cascading Failures: Overheated motors can bring down entire systems—pumps, fans, conveyors—impacting production and reliability.

Mitigation Tips:
Use motors rated for higher ambient temperatures.
Maintain effective cooling and ventilation systems.
Monitor temperatures with RTDs or thermistors.
Plan for proper derating in design.
Perform regular lubrication and bearing maintenance.

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Setting Your Thermostat—and Protecting Your Motors

Reducing wear and tear on your HVAC motors starts with smart temperature settings. According to the U.S. Department of Energy, setting your air conditioner to around 78 °F (26 °C) when you’re home strikes a balance between comfort and energy savings (DOE).

They explain that the smaller the difference between indoor and outdoor temperatures, the lower your overall cooling bill will be. Every degree lower than 78 °F can increase energy use by 3–5 % or more. For your HVAC system, that means motors must work harder and run longer, increasing stress, heat buildup, and failure risk.

By setting your thermostat at a moderate, recommended level, you reduce excessive cycling and allow your motors to operate within safer thermal limits—helping prolong their lifespan and save on maintenance costs.

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How Dreisilker Can Help

At Dreisilker Electric Motors, we’re ready to support you—even on the hottest days:

Counter Sales Support

Our experienced team helps you choose the right motor or part for high-temperature applications. Whether you need HVAC blower motors, capacitors, bearings, or industrial drives, our counter sales experts ensure you get the right fit for your needs.

Expert Motor Repair Services

When heat takes its toll, our repair shop can rewind, rebuild, and restore motors. We inspect and test the entire motor, make the necessary repairs, and return your motor to peak operational condition.

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Bonus Tips From Our Blog

For even more practical guidance on keeping your home cool and your AC working at its best, check out our blog:
Get ACs Bumping: Ice-Cold Air When Heat Overwhelms Home

We are Now Open in Carrollton, Texas!

 We’re excited to share some big news—Dreisilker has officially expanded to Texas! Our new Carrollton location is open and ready to serve businesses throughout the Dallas-Fort Worth area with motors, HVAC components, and expert support.

For nearly 70 years, Dreisilker has been a trusted name in motor solutions, delivering reliable service, extensive inventory, and deep industry expertise to contractors, facility managers, and industrial businesses. Now, we’re bringing that same commitment to Texas businesses looking for dependable motor solutions.

Why Texas?

As industries continue to grow in Texas, so does the need for motor solutions. Our expansion to Carrollton is part of our commitment to serving businesses where they need us most. Whether you need motors, parts, or expert guidance, our team is here to help.

“Expanding into Texas is an exciting step for Dreisilker. We’re ready to bring the expertise and service that has made us a trusted name to businesses in Dallas.” – Zac Zych, VP of Sales.

With our Carrollton location, customers can expect quick access to inventory, expert advice, and the same level of customer-focused service that has defined Dreisilker for decades.

“Texas has a thriving industrial and commercial market, and we’re proud to bring our decades of experience to support local businesses. Our Carrollton location reflects our commitment to growth, customer service, and providing the best motor solutions in the industry.” – Leo Dreisilker, President

Visit Us in Carrollton

We’re officially open for business, and we look forward to working with you! Whether you’re looking for motors, HVAC components, or expert support, Dreisilker is here to keep your operations running smoothly.

 

Dreisilker Electric Motors

2120 Hutton Dr, Ste 200

Carrollton, Tx 75006

p: 972.635.5293

Dreisilker.com/carrollton

Thank you for being part of this exciting new chapter with us!

Are you storing electric motors for temporary or indefinite use? Proper storage for electric motors is essential for your equipment. In the long term, properly storing your motor can help maintain its performance and reduce repair costs. Dreisilker, with over 68 years of experience in electric motor repair, provides a motor storage program so you don’t have to worry about storing your motors on your own.

When it comes to storing electric motors, there are several important components to consider. Specifically, proper environment and bearing maintenance.

The Environment of your Electric Motor Storage

It’s critical to make sure the environment where you store your electric motor is kept at optimal conditions.

Climate control

Humidity and temperature vary by type of motor, but in general it should be stored in a temperature-controlled space that is not too humid. Temperature fluctuations caused by constant naturally occurring heating and cooling cycles should also be avoided.

Threat of contamination

Electric motors should be stored in a clean environment in order to prevent contamination to the motor. Taking the extra step of covering the motor in a cardboard box or a tarp can prevent dust and other contaminants entering the electric motor.

Rodent control

Rodents such as mice or squirrels are known to cause havoc on many things, such as electric motors. Ensuring that the space where you store your electric motors is critical so that you don’t have any unexpected chewed wires or contamination from rodents nesting in your motors.

Bearing Maintenance for Electric Motor Storage

Another important factor in storing your electric motor is turning the bearings regularly. Bearing maintenance helps prevent the formation of rust, which can lead to a complete failure of the system. This can be accomplished by hand, but if you don’t want to take that approach, Dreisilker’s motor storage program can turn the bearings for you as part of our storage cycle.

When Should you Store a Spare Electric Motor?

There are many factors that go into deciding whether or not you should keep a spare electric motor on hand. Some factors include how common the motor is, how critical the motor is to your operations, and cost of a spare. Check out our guide here:

The bottom line is that properly storing electric motors is one of the most important factors in making sure that your machinery is safe and runs smoothly. Dreisilker’s motor storage program provides a service for turning bearings during storage and protection from atmospheric contaminants, so you don’t have to worry about storing electric motors on your own. With the help of Dreisilker’s motor storage program, the longevity of your motor and its performance can be maintained and repair costs can be saved.”