• ABB showcases next-generation technology and digital solutions to extend turbine lifetime and boost performance.
• Generator replacements in just 5–10 business days help wind park operators avoid up to EUR 1.2 million in losses per turbine.
• The new production line increases ABB’s stator manufacturing capacity, enabling faster, more scalable support for industrial sector.
As the global energy transition accelerates, wind energy is becoming a cornerstone of the future power mix. The International Energy Agency estimates that renewables will account for almost half of global electricity generation by 2030, with the share of wind and solar PV doubling to 30%. As new capacity continues to grow, repowering aging wind farms presents a significant opportunity to enhance efficiency, extend asset life, and lower operational costs.
To meet this demand, ABB has significantly expanded its motors and generators manufacturing facility in Jüri, Estonia, launching two major initiatives: a new Center of Excellence (CoE) for wind generator services and a large stator production line to Large Motors and Generators factory.
The new CoE offers advanced repair and refurbishment services for wind generators. It addresses common issues, such as insulation degradation and mechanical fatigue, utilizing ABB's latest technology upgrades to enhance generator reliability and performance. All capital spare parts used are brand new and sourced directly from the factory, offering high quality and long-term durability. On average, generator repair times are 50% shorter compared to purchasing a new unit delivering operational efficiency and enabling industries to do more with less by reducing material use, waste, and energy consumption without compromising reliability or performance.
“The CoE in Estonia is more than a service center - it is a strategic enabler for long-term performance, designed to deliver what wind operators need most: speed, reliability, and lifecycle support,” said Daniel Gerber, Business Line Manager, Renewable Power, Motion High Power Division. “Backed by ABB‘s global expertise and decades of experience in mission-critical applications, we combine rapid generator replacement, advanced refurbishment capabilities, and predictive maintenance solutions to help our customers reduce downtime, extend turbine life, and transition to digital asset management.“
"ABB’s decision to expand production and establish its global wind turbine maintenance center in Estonia is a significant recognition for Estonia’s economic environment," said Minister of Economy and Industry Erkki Keldo. "The fact that Estonian engineers have been entrusted with one of the most complex manufacturing processes in Europe demonstrates that our experts possess skills of the highest international standard. As a nation, the creation of several dozens of new highly skilled engineering positions is of considerable importance, supporting research and development activities, increasing the company’s added value, and further strengthening Estonia’s standing as a country of advanced technological manufacturing."
Through its Generator Stock, ABB guarantees the fast replacement of commonly used wind generators within roughly 5–10 business days, helping wind park operators avoid downtime losses of up to EUR 1.2 million per 3.6 MW turbine, a substantial improvement over the typical 22–25-week lead time for new units.
The new large stator production line increases ABB Estonia’s manufacturing capacity, enabling the production of generator stators of up to 60 MW, a big leap from the previous 20 MW limit. For comparison, ABB’s new production capability supports stators with three times the power output of the 20 MW main propulsion motors used in Tallink Group’s high-speed shuttle ships Megastar and MyStar, also supplied by ABB. The stator is the main component in electrical machines, turning the rotating magnetic field into electric current.
A newly opened showroom at the CoE offers customers firsthand insight into ABB's precision manufacturing, stringent quality standards, and digital tools, reinforcing ABB's commitment to innovation, transparency, and helping industries outrun - leaner and cleaner.
