Repair and retrofit – sustainable solutions for existing systems

Transformers, chokes, and filters are key components in many industrial systems and rail vehicles. Instead of completely replacing them when they become defective or technologically obsolete, repairs and retrofitting offer an economical, sustainable, and technically high-quality alternative. Both approaches aim to extend the service life of existing products, increase their performance, and adapt them to current technical requirements.

Repair – restoration and value preservation

Repair is the process of restoring a defective or damaged object to its original function and performance. At Bächli AG, this process involves thorough analysis, precise planning, and professional implementation by experienced specialists.

Goals of a repair:

Restoration of functionality: The product is repaired so that it is fully operational and safe again.

Extension of service life: Weak points are specifically remedied or improved in order to significantly extend the service life.

Safety: All applicable standards and regulations are complied with, so that the repaired transformer can be operated without restrictions.

Cost efficiency: Repairing saves considerable costs compared to purchasing new equipment and reduces downtime.

Phases of a repair at Bächli:

Diagnosis: Our experts analyze the defect in the test lab, identify the cause, and document the results.
Planning: Creation of a detailed repair plan including material requirements, time frame, and costs.
Offer:
Basic offer: Repair or 1:1 replica with complete documentation.
Optimized offer: Recalculation and technical optimization to increase performance and improve operational reliability.
Procurement: By working closely with our suppliers, we shorten delivery times and stay on schedule.
Execution: Professional implementation by experienced employees in our production department.
Testing and validation: Comprehensive testing of function and safety – documented and traceable.
Documentation: All work steps, materials, and test results are archived, making it possible to replicate the process at any time.

Examples of repair measures:

Replacement of individual components (e.g., windings, insulators, fuses).
Rewinding of coils to optimize performance and reduce downtime.
Replacement of the iron core to improve efficiency and energy efficiency.
Optimization of insulation to increase safety, durability, and noise reduction.

Advantages of the repair

Sustainability: High proportion of recycled materials and conservation of natural resources.
Cost savings: Significantly lower overall costs compared to purchasing new equipment.
Fast implementation: Shorter downtimes thanks to efficient processes.
Preservation of proven systems: Existing systems remain in reliable operation.
Expertise: Professional execution thanks to decades of experience at Bächli AG.

Our mission is to preserve, improve, and optimize what already exists. Whether it's a minor repair, complex overhaul, or reconstruction, we offer you a solution that is economical, technically sound, and sustainable.

Retrofit – modernization and future viability

While a repair restores the original function, a retrofit goes one step further: it modernizes the existing product and brings it up to the latest state of the art. For transformers or chokes, this means integrating new materials, optimized calculation methods, and improved designs—without having to replace the entire system. Compatibility with existing systems is a key consideration in retrofit projects. It is often crucial for customers that no changes need to be made to the surrounding system. That is why retrofit products are developed in such a way that existing installation spaces, mounting points, and connection points can continue to be used. This means: the same hole patterns, identical connections, and precise dimensions – for quick and easy replacement. This eliminates the need for costly modifications, keeps downtime to a minimum, and allows the modernized system to fit seamlessly into the existing infrastructure.

Objectives of a retrofit:

Performance enhancement
Improvement of energy efficiency and reduction of losses.

Safety improvements
Adaptation to current standards, installation of modern protection systems.

Improved comfort
Optimizations in size, weight, and ease of installation.

Increased service life
Replacement of critical components to ensure many more years of operation.

Cost savings
Reduction in maintenance and operating costs thanks to modern, low-maintenance components.

Retrofit in practice

By recalculating and adapting existing designs, transformers can be adapted to new requirements - such as higher power densities, lower noise levels, or improved heat dissipation. The basic structure remains unchanged, while the internal technology is

brought up to date.

Cost efficiency: Significantly cheaper than purchasing a completely new system.
Sustainability: Reusing existing components reduces waste and resource consumption.
Fast implementation: Individual adjustments and technical improvements can be made easily.
Flexibility: Technical improvements and individual adjustments are possible without changing anything in the surrounding system (existing installation spaces, existing hole patterns, or identical connections can be retained).

Retrofit – modernization and future viability

Challenges that Bächli masters:

Technical complexity: Integration of new components into existing systems.
Cost control: Early and precise calculation to avoid unforeseen additional expenses.
Business interruption: Early planning enables minimal downtime and smooth project processes.

Conclusion – economical, sustainable, future-proof

Whether repair or retrofit – both options offer companies the opportunity to maintain existing systems in the long term, reduce costs, and conserve resources. While repair restores the original condition, retrofitting leads to targeted modernization and increased performance.

Bächli AG combines decades of expertise, precision manufacturing, and state-of-the-art testing and calculation methods to get the most out of every project—for durable, efficient, and safe products that will continue to exist in the future.