The podcast discusses the shortage of electric transformers, with lead times exceeding two years and prices soaring over 60%. They explore the reasons behind the shortage, such as rising demand from renewables, storms, federal investment, and EV chargers. The housing market crash of the 2000s made manufacturers cautious, while labor shortages and new DOE rules add to the challenges.
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Quick takeaways
Rising demand for transformers has led to extended lead times and increased prices, affecting various industries.
Manufacturers struggle to expand capacity due to labor shortages, unique steel requirements, and regulatory uncertainties.
Deep dives
The Persistence of Long Lead Times for Transformers
Despite various industries returning to normal post-COVID, the transformer market has faced sustained challenges in lead times. 2020 brought disruptions, specifically in transformer lead times, creating ongoing issues. With lead times still reaching up to 125 weeks for certain transformers, planning for projects becomes incredibly difficult, leading to struggles for utilities, real estate, and startups in particular.
Historical Perspective on Distribution Transformer Demand
In 2018, customers were accustomed to receiving distribution transformers within 12 to 14 weeks. However, rising demand quickly outpaced manufacturing capacity, leading to longer lead times. The surge in demand combined with limited manufacturing capabilities resulted in unpredictable lead times and a challenging market environment.
Challenges in Expanding Manufacturing Capacity
As demand for transformers surged, manufacturers found themselves operating at full capacity, making expanding production a challenging task. Factors such as labor shortages, rural production locations, and equipment availability complicated efforts to ramp up manufacturing. Additionally, the unique steel requirements for transformer cores added another layer of complexity.
Regulatory Factors and Price Impact on Transformers
Regulatory changes from the Department of Energy proposed higher efficiency standards, potentially impacting manufacturing processes and requiring shifts to alternative materials like amorphous steel. Price trends for transformers saw a significant increase of 75% to 100% over the last few years, placing financial strain on utilities and end consumers. Amidst the challenges, efforts to expand manufacturing capacity are underway to address the supply chain bottleneck and alleviate the current market constraints.
The list of things that depend on transformers is long: new housing, EV chargers, renewable projects, and more. That’s why skyrocketing lead times and prices for grid equipment that raises or lowers voltage is a real problem.
The wait for a new transformer has jumped to over two years, according to WoodMackenzie. Back in 2020 it took just a few months, according to Tim Mills, CEO at transformer manufacturer ERMCO. WoodMackenzie found that prices, meanwhile, have risen over 60% since 2020.
So what’s causing the shortage?
In this episode, Shayle talks to Tim about how rising demand for transformers has pushed manufacturers to capacity – and why it’s been so hard for manufacturers to expand that capacity.
They also cover topics like:
The state of the shortage, including prices, lead times and types of transformers that are in especially short supply.
The major drivers of demand growth, including renewables, storms, federal investment, and EV chargers.
How the housing boom and bust of the 2000s left transformer manufacturers wary of bubbles in demand.
Why the tight labor market makes it hard to expand manufacturing capacity.
How new rules proposed by the Department of Energy are throwing uncertainty into what type of equipment manufacturers should invest in.
Recommended resources:
WoodMackenzie: Supply shortages and an inflexible market give rise to high power transformer lead times
T&D World: No Easy Answers: Transformer Supply Crisis Deepens
Catalyst is supported by Antenna Group. For 25 years, Antenna has partnered with leading clean-economy innovators to build their brands and accelerate business growth. If you’re a startup, investor, enterprise or innovation ecosystem that’s creating positive change, Antenna is ready to power your impact. Visit antennagroup.com to learn more.
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