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TPI Files Bankruptcy, Ørsted Fundraising Round
The crew discusses TPI Composites’ chapter 11 bankruptcy filing and Ørsted’s $9 billion fundraising amid financial challenges. Joel gives an update about the 2026 Melbourne Wind O&M Conference.
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You are listening to the Uptime Wind Energy Podcast brought to you by build turbines.com. Learn, train, and be a part of the Clean Energy Revolution. Visit build turbines.com today. Now here’s your hosts, Alan Hall, Joel Saxon, Phil Totaro, and Rosemary Barnes.
Allen Hall: Welcome back to the Uptime Wind Energy Podcast, Joel Saxon.
Is in Australia. You want to tell everybody where you’re at at the moment?
Joel Saxum: Yeah, we’re down in Melbourne. I’m here with Matthew Stead from Ping as well. Uh, Rosemary was supposed to join us, but uh, of course she’s under the weather. Uh, but we are down here doing basically a, a tour to Melbourne, uh, I guess you could say, of the wind industry.
So if you don’t know in Australia, a lot of the wind operators, uh, and ISPs, uh, and OEMs, to be honest with you. Are located here in Melbourne, uh, and we are talking to them all about the conference that we’re gonna put on this February. Uh, it is a, the, the new and improved version of the, [00:01:00] uh, successful one we did last year.
So we’re taking the feedback that we got right after the event last year, uh, connecting with these, uh, all the stakeholders down here and seeing what do they, what do they want to hear for the next one? What did we do well? What could be better? Uh, we’re looking at venues, we’re doing kind of all the above to get this, uh.
Conference up and running, and I know, uh, Matthew and I, I think we’ve had four to five meetings a day, every day. Um, thank you to the people that we’ve met with, if you’re listening, because it’s been really good for us, uh, very engaging, lots of feedback. So I think we’ve got a, we’ve got a good list of speakers lined up and then also, um, content for next year.
That’s great. So what we’re looking at right now as well, uh, if you’re inking this on your calendar. For the, uh, wind energy o and m 2026 conference here in Melbourne is February 17th and 18th. This year we’re gonna do two full days of, uh, panel discussions, round tables, and all kinds of information sharing.
[00:02:00] Uh, the goal, of course, just like last year, gather up some of the smartest people in wind and share strategies that you can take back, uh, for operations and maintenance and, and action within your company.
Allen Hall: And Phil Tarro of Intel stores out in California. And Phil, this has to be one of the. Busiest weeks in wind on the investor side.
So much happening. Osted, uh, is going to issue a $9 billion emergency fundraising round. And I want you to frame this a little bit. I, I, I’ve heard so much on the news and been reading a lot about this, but there’s several undertones, several things happening at the same time and there really hasn’t been a clear path as to why.
Osted has decided to go forward on this fundraising round?
Phil Totaro: Well, effectively it stems from two big things. One is obviously they had shown some financial losses, uh, recently, and this is going back a couple of [00:03:00] years now that had necessitated. You know, companies like EOR coming in and taking a 10% stake, um, just to bolster them again, we, we talked on the show before about the fact that they’re not necessarily wanting to take over, although now there’s some people in, you know, Denmark, that are kind of pushing the Danish government to sell off their chunk.
And the presumption is that it would be sold to, to somebody like eor. So we’ll still see if that’s possible or even. You know, uh, likely to happen, but there’s a project here in the United States called Sunrise Wind, which Ted was hoping to sell off a chunk of to a co-investor and. Because of some of the rule changes around, um, tax credit qualification, they’re probably not going to be able to move forward in the way that they had hoped to, um, with that stake sale.
And as a result, [00:04:00] it’s leading them to absorb a lot of the, um. You know, financial losses from, you know, some of the delays and, and other issues that they’ve had with getting a lot of these offshore projects, you know, uh, up and running. Uh, it’s, it’s kind of forcing them to do this capital raise to be able to provide themselves with enough cash to be able to continue operating.
The
Allen Hall: Sunrise Wind Project was a partnership between Orit and Eversource, and Eversource pulled out of that roughly a year ago. And the other one, which had a partner that, uh, Ted had who pulled out was for Ocean Wind one and two, which was PSEG, which is a New Jersey power company. Eversource being a northeastern power company, essentially those two pulled out like in 2023 and 2024 when the price of steel went up, inflation was high, the cost of the projects went up.
So they’ve been out for a little while still. [00:05:00] It was in that interim that Osted just wasn’t able to find anybody to join in on those projects. And it does seem strange, and again, I want to get to this point. All the US investment and offshore, all the US companies are all out. Basically you have EOR and you have Osted Dominion.
Dominion. Okay, that’s true. But Di Dominion is sort of a different animal.
Phil Totaro: The the reality is, yes, is the short answer to your question, Ellen, that they, they had tried to find another co-investor after, um, Eversource pulled out. The challenge with that was that there. Has has also been, um, an effort by the project developers to try and renegotiate the PPA prices.
Eversource was gonna be one of the main off takers for this. They don’t wanna have to absorb a significantly higher price. And then have to find ways of passing [00:06:00] that on to to customers. And it’s also what led to this challenge of sted not being able to find a new co-investor after Eversource pulled out.
Um, you know, with interest rates being so high. And not being able to renegotiate the PPA anymore. Y you know, the developers that are still, you know, have their lease areas and, and are pursuing their projects. They’re locked in to whatever they’ve got at this point. If nobody else wants to come on board, then it’s up to Ted to basically eat the entire cost of this thing and thus, you know, a major contributor to the capital raise.
Allen Hall: So the discussion online is that the Trump. Administration sort of forced this to happen. That isn’t necessarily correct. I think a lot of this has started a year or two ago. You remember also. Phil with Ocean Wind one and two, the exit fees with the state of New Jersey. I think that Osted was [00:07:00]going to have to pay somewhere around $300 million to the state of New Jersey, and I think they ended up paying less than half of that at the end.
But it’s still a lot of money. There’s a lot of money in exit fees that Osted has paid over the last two years roughly, or, or buybacks. They, they paid Eversource to get
Phil Totaro: out. Essentially just to also clarify, you know, what, what the administration’s done has not helped. I think we can all agree on that. The, but the reality of it is that yes, they, they were already in a bad situation that got made even worse by.
Increasing the risk of, you know, particularly a foreign investor coming in and, and being a co-investor in, in this project. Obviously there are any number of utility companies in the United States that could have, you know, uh. Co-invested in, in this project along with Sted. They chose not to because they don’t like the economics of offshore wind.[00:08:00]
Uh, and that’s just the, the reality at this point in time. Uh, I mean, duke Energy this week, or I guess last week as, as this episode airs also just announced that they’re gonna cancel their two North Carolina projects because of the same thing. It’s, it’s basically down to the economics of the project.
And at the end of the day. If you’ve got somebody in the administration that’s making, you know the, the investment environment look even worse than what it already was before he even came into office, then it’s going to necessarily, you know, take more options off the table for. Potential investors that could have come in and at least helped, uh, kind of share the, the risk and, and, you know, reduce the amount of, of capital outlay that OSTED would’ve had to make just by themselves.
In my
Joel Saxum: mind, with this new kind of like P-T-C-I-T-C cliff coming, there’s no [00:09:00] reality where, uh, capital gets cheap enough, interest rates get low enough in time for any of that to change like that, that’s just not gonna happen. We’ve got 18 months and we need to, it would have to come down by percentage points, not basis points.
And I don’t think that’s going to, there’s no reality of that happening. I think
Allen Hall: that’s true, generally speaking. Right? But I think the problem is, is where are the New York’s and the Massachusetts of the world gonna be able to get power from? They need this, they really do need offshore wind. The prices of electricity there, uh, if you’re a consumer, is about $300 a megawatt hour.
That’s what I was paying in Massachusetts to buy power on the grid. So $150 a megawatt hour coming off of the, uh, you know, offshore wind farm. Yeah, wholesale still is, is high compared to other parts of the United [00:10:00]States, but as it’s half of what I was paying as the consumer. So there
Phil Totaro: is, uh, a dichotomy there, right?
Yes. But keep in mind, that’s only for the generation cost. So where, where I am in California, I pay basically $380 a megawatt hour for electricity as a consumer. Now half of that. Is generation. The other half is, uh, split between the transmission and distribution cost plus the overhead to Southern California Edison as the utility.
The reality is that yes, the, the generation cost may be 150 bucks, but they’re still gonna have to raise prices for consumers to be able to sell them the power because you have to factor in the transmission and generation cost, and they’re gonna wanna maintain at least a 20% overhead on all that. And because that’s literally their profit margin.
Allen Hall: Well, Phil, what I’m trying to get at is the other half of the equation, the [00:11:00] transmission distribution piece is not cheap. So we, we force all the, the generation side to be as low as possible, but the people in the middle, it’s the middlemen, as they would call it, are taking a substantial amount of the money that you’re paying for electricity today.
So yes, offshore wind is expensive. So is transmission and distribution. And you would think something has been around for 30, 40, 50 years, transmission and distribution, most of it in the United States has been around at least that long. You think that the cost of that would come down over time and it really hasn’t.
Uh, which the economics doesn’t make any sense about that. So when it’s, when we’re talking about Ted, like, yeah, yeah, yeah, all this is not great for Ted, but there is something wrong with the system
Phil Totaro: where Ted can’t make this work. Which is also why we probably shouldn’t have the government canceling transmission projects because we need them and taking, you know, 700 million plus [00:12:00] dollars out of the, um, you know, department of Energy’s grant budget for transmission projects.
I mean, this is a time when we need a lot of that technology, but because it has any association with wind and solar, it’s getting pulled. So, uh, you know, uh, that’s a, that’s a decision that’s been made by the DOE
Joel Saxum: Phil and I, and I back this one up. I saw this just, uh, yesterday. I think there was like a, a double digits coal projects pushed forward.
I don’t know if you saw that. There was like a, there was a pre, there was a press release where there was like something like 11 coal projects or something like approved to move forward and it’s like. This is, this is yesterday. This is yesterday’s technology. We’re moving forward. Why are we pushing coal?
And there was a guy on Fox News talking about it, and he was saying. They were saying like, well, have you made strides for coal to be cleaner? Because of course you have. And he was like, no, there’s always gonna be a footprint. [00:13:00] Like there was no, there was no like, yeah, we’ve done this clean coal thing. He’s like, ’cause Trump deal talked about it as clean coal.
And uh, they were like, well, you know, it’s coal. There’s always gonna be a footprint with mining. So
Allen Hall: yeah, that’s our re that’s our reality. Are we still gonna dig rocks and then burn them? Is that the plan? Because it does seem a little bit easier to take the wind and turn it directly into electricity.
Same for solar. Turn the sun into electricity without having people digging rocks and moving rocks and transporting rocks and trails to rain and fires and the whole bit. It’s insane
Phil Totaro: right now. Well, for those that also don’t understand wind and solar, by the way, contribute $3.5 billion annually to. Lease payments to landowners directly and to state and federal tax coffers.
So, you know, you, you wanna explain why that’s not [00:14:00] worth something. I’m, I’m prepared to hear it as an American citizen. You can also explain to me, if you’re the government, why you’re canceling lease auctions at Boem, that would’ve generated $1.8 billion for the federal government. That’s revenue that you’re literally throwing away.
Even if you don’t like wind, you don’t wanna see it. It wasn’t not like it, it’s not like it was gonna get built during, you know, his presidency anyway. Why not at least take the money? And then the project developers can go build it, which by the way, they’re gonna do anyway. They can just go build the projects after you leave office.
So you know what? You can’t paint yourself as being pro-business when you actively turn away money.
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I’ve used the word cliff to describe the drop off to rosemary the other day. It dropped a ton. It hasn’t. If you, I went back and looked at like the 10 year on Sted stock. It was doing great in like 20 20, 20 21 just after COVID, and it’s come down quite a bit since then. But Sted, as an organization is still making money now, not making money as fast as they were before, but they’re still making money.
What? Does this really mean in terms of the long-term outlook for Ted?
Joel Saxum: Well, I know it’s, it’s got the industry of buzz, right? I think I, I woke up, uh, of course I’m in Australia right now, so the time zone’s a little weird, but I woke up with a large handful of [00:16:00] messages from friends around the world. Did you see Orid stock price?
Did you see, or stock price? Um. I think that, uh, I mean, we’ve kind of, we know the situation we’ve talked about on the podcast a lot about what’s going on in offshore wind and the, you know, the impairments on projects and the difficulty in financing and kind of the headwinds that they’ve been facing or as a whole.
Um, at the end of the day, you can see, because I, this is my take, you know, I’m not an economist, but when I looked at, um, how the stock price fell and then it flattened right off. It was like, well, cliff, and then straight off I was thinking, okay, this is institutionalized money that understands what’s going on here and you lower that price than there’s the stock offering, so there’s a cheaper way to get into, or Ted here.
I don’t think it’s gonna affect the long, long term outlook of the company. Like the immediate stock share pricing dropped like a third. That sucks. Right? But it’ll come back, I think, and if you look at, like what you said, the 2020 on [00:17:00] trend, that trend follows a lot of other pure play wind companies as well.
I mean, I guess I, I, I would, I would consider or set a pure play wind company, even though they’re probably 90%. Because they dabble in some battery stuff and V two X stuff and some hydrogen, whatever, but they’re a wind company. Um, and if you watch the trend of other companies in the same space, like they’ve been getting beat up for the last four or five years, uh, during this COVID play, um, or since then.
So I think that, again, the long term run for them, they’ll, they’ll be healthy. They’ll come outta this, they’ll raise some money, um, make some moves so that, I don’t think it’s gonna be a big issue.
Allen Hall: Phil, same thought. Is it gonna be a big setback for Ted or are they gonna need to. Try to sell off some assets because that’s the talk around the industry is that.
They’re gonna do this fundraising effort, but at the same time, they’re gonna try to offload a couple of projects or things that have value today to improve their long-term forecast.
Phil Totaro: Yes. And I [00:18:00] would concur that that’s likely, but that’s also not to freak anybody out because Yeah, I mean, companies normally do this kind of an what they call an asset rotation.
Up until now, particularly with their offshore portfolio, they’ve owned. Almost a hundred percent of most of their projects and only, it’s only been in the past, like five years that they’ve even been adopting the philosophy of going in and getting, um, investment partners to come along with them. Um, and it’s, it’s also, uh, you know, it’s something.
That, that’s been possible through the capital markets as well. The, the problem for them is that they negotiated poorly probably about three, four years ago on some of these contracts that they worked out, particularly for the power offtake in places like New York or New Jersey, et cetera, that led them to these, um, you know, big.
You know, fees for pulling out of [00:19:00] projects and, and cancellation fees, et cetera, et cetera, that, um. It, you know, left them with a lot of, uh, debt and other kind of cash related liability on their books. So the capital raise is necessary. The, the project, um, you know, asset sales and, and things like that, the asset rotation that they can undertake, that’s also necessary in all likelihood.
My concern for Sted, the bigger concern here is. Whether or not they are really going to. Keep flowing cash into potentially unprofitable ventures.
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Uh, there is a lot of questions about TPI at the minute. They have an order book and they push out like 6,000 blades a year, something around that number. Oaktree capitals come in, it has backed them. [00:21:00] Chapter 11, if you’re not familiar with bankruptcy Methods, chapter 11, it allows you to continue to operate and reorganize and restructure your debt.
Chapter seven and some of the other ones are pretty much an immediate shutdown. So TPI is going to continue making blades or getting some funding. But Joel, this is actually a big hit to the GEs of the world who rely on TPI to produce blades. Is it though, right,
Joel Saxum: because you usually, in chapter 11, you usually have like a tiered, a tiered debt structure too, right?
There’s like, there’s Class A, class B, class C, right? So their debt to A TPI is normally gonna be. Raw materials, uh, logistics, those kind of things. Unless, and I don’t know how they do their business. Right. There may be a case where you’re like, ’cause TPI does a lot of work with ge, right? They may have ge, GE may be doing the logistics on their end, so that might not even be on TPIs side of things.
So it’s like. Building rent, [00:22:00] um, you know, uh, capital assets. So if they have loans out against buildings or some things like that, right. Those are usually class A type things where they get paid off first. It’s a little bit rocky, but they’re, they’re able to continue to work, right. So it’ll be, they’ll, they’ll be some changes, but it, they, it shouldn’t upset the wind industry.
Like it shouldn’t have set the supply chain.
Allen Hall: Well, it does introduce another layer of bureaucracy because once you enter into chapter 11, you can’t. Buy supplies, you can’t sell things as easily. It, it becomes much more transactional. You have to have approvals to, so you can’t start selling off assets behind the scene.
Chapter 11 is a very structured environment that you have to operate in. You don’t want to be there if you can avoid it because it just makes things harder to do. But at the, at the same token, and Phil, maybe this is where part of the problem is, they have plenty of orders. But are they getting paid on time?
Which is my first question. Had they been getting paid when they should be getting paid? [00:23:00] And then second has quality issues, uh, about a year or two ago, sort of stacked up where they’ve had to do warranty claims and spend a bunch of money that they weren’t expecting to. Is that what led to this, uh, eventual chapter 11 filing?
Phil Totaro: Yes, all those did contribute. They also had issues, uh, and unexpected costs associated with their expansion. They had some strikes in Turkey where people wanted more money. Um, you know, there were any number of things that that occurred. But I, I wanna go back to this notion that they have up to $10 billion in liability on.
You know, uh, a company valuation of, what did you say before, Alan? It’s like a few million dollars market cap right now for TPI is $7 million and that’s down from a hundred million a couple months ago. That’s extremely concerning, uh, considering the fact. That a, they have such a wide range, you know, between 1 billion and 10 billion.
And [00:24:00] secondly, that obviously stems from the quality issues that go back a number of years. So, I mean, I remember us talking about it a year or two ago on the show about how they’ve brought, you know, uh, quality experts in and, uh, you know. Manufacturing head chief Technology officer, uh, even the CEO got replaced, uh, at one point because of, um, some of the quality issues that they had and how it was being handled by the previous management.
So presumably this is part of a strategy to, you know, again, restructured the debt certainly, but it. You know, these, the liability issues could still persist. Um, because even though, you know, you’re getting bankruptcy protection in chapter 11, um, nobody’s gonna want to come in and buy the company anyway.
You know, they, if they had entered chapter seven where it was a liquidation, then that’s [00:25:00] a scenario where you could have, you know, I, I wouldn’t necessarily. Necessarily say it would’ve been GE Renova comes in and, and buys them. But, um, it could have even opened up the opportunity for, you know, a foreign company to come in because their factories already have, uh, tax credit qualification.
Um, and so somebody could have stepped in and, and, you know, taking that over, but. This is, uh, uh, just the recognition that, okay, if they’re in chapter 11 and they’re restructuring their debt, it doesn’t mean that the debt goes away. It might get reduced. Um, and hopefully it gets reduced if it’s $10 billion.
Um, but because that’s, I mean, that’s literally almost their entire fleet of blades needs to be, yeah. Would need to be replaced.
Allen Hall: Yeah. And, and Joel, I think this is the real crux of this is. You can’t have a billion dollars in debt and operate a blade factory. [00:26:00] That doesn’t make any sense. Do they eventually clear this out?
What do you think is going to happen to TPI do. They just continue to operate. No one has any interest in it. They just continue to make blades and bring in some revenue and restructure the debt. I, I don’t see this ending
Joel Saxum: ending. Well, chapter 11 sometimes is a gateway drug to. Shutting the doors. Yeah.
That could be happening. And then, and then it’s fire sale because then the lawyers step in and you know, there, there’s oversight there. And someone could pick up the assets or the assets get parted out to try to pay back the debtors or the creditors, sorry. Uh, so you could see other blade companies, you could see some something odd or Sonoma and Aris, or of course, I don’t have the insight into those as much as.
Maybe Phil does, but you could see someone else buying this assets.
Phil Totaro: Yeah, it wouldn’t be Sonoma right [00:27:00] now because of the foreign ownership thing for the tax credit qualification, Joel. Um, but there are, you know, you mentioned one company that, that could be interested and has expressed interest in, you know, getting a, a footprint in the us but there’s also companies, you know, in, uh, other parts of the world that.
You don’t want to have a presence here in the States, uh, that wouldn’t necessarily be subject to, you know, the, the foreign entity qualification, uh, restrictions to qualify for tax credits. So there are possibilities for this long term. Does
Allen Hall: it leave a door open for a company to come in and clear the books, settle the debts on some level, and then you continue on as a restructured company?
Joel Saxum: Or this, or think about this one. And, and this is, this is a long shot, right? But does it leave a door open for someone to watch TPI fall on their face and start [00:28:00] up a blade company?
Allen Hall: I don’t think so. That’d be hard because there’s so much, there’s so much momentum right now with TPI. It’d be really hard to do that, be like, I’m gonna use an aerospace equivalent.
It would be like Boeing Aircraft and Spirit. And Spirit was Boeing at one point, then broke off and set up their own company and was supplying pretty much all Boeing. Uh, parts, but Boeing has reacquired it because it came in in trouble, very similar to the TPI situation. Not that TPI was owned by an OEM, but it does sort of lend itself to ge.
Renova designs are coming through TPI all the time in a couple of the manufacturers, for that matter. Somebody’s gotta do something. They need parts.
Phil Totaro: Yes, but here’s, here’s the reality and ’cause I’ve actually studied a bunch of the different m and a deals that have happened in wind energy over the years.
What happens in most industries with m and a is healthy company buys smaller, healthy, but growing company. In [00:29:00] wind energy, we don’t really have that. When m and a happens, it’s usually healthy company gobbles up assets of, you know, unhealthy company that are still valuable and then leaves the debt to somebody else like, and that’s why.
The chapter 11 thing is interesting because if they’re restructuring the debt, it means they can reduce it a little, but the debt is still gonna be there. If I’m going in and saying that the company’s worth 7 million in a valuation, but they have a billion dollars in debt even after, or during chapter 11, I’m not buying it.
Um, because who wants to absorb that? Nobody, nobody wants to do that. So the reality is, what Joel mentioned is are people gonna watch while this thing falls on his face? And then out of the ashes of, of this something new, uh, arises? Yes, I will actually agree with and support that notion. Not that I’m hoping TPI fails, but.
That’s [00:30:00] more likely to happen if the worst transpires and TPI can’t pull themselves out of this. That is more likely to happen than some, you know, angel investor, uh, or angel of an investor, uh, swoops in and, and grabs them up and, and says, you know what? We’re, we’re gonna. You know, keep you healthy and keep you going because you’ve got this $1.6 billion order book.
What, what we have in the wind industry are vultures who come in and they start plucking away at that $1.6 billion worth of order book and taking it for themselves. And, you know, the remnants of that carcass can go, you know, die in the desert somewhere.
Allen Hall: No, I, here’s, here’s my. 30,000 foot view of TPII hope they can make this work.
There’s a lot of workers and a lot of the wind industry that relies upon them. They cannot close. They need to keep producing and, and everything that’s happening in the world right now, uh, with Sted [00:31:00] is not great. But TPI has a bigger impact I think. In terms of where we’re going over the next five to 10 years, we need blades.
TPI makes a lot of blades. They’re pretty good at it, but the financial situation is just not good at
Phil Totaro: the moment. And keep in mind too that because of these changes in the law for production tax credits and investment tax credits, TPI needs to keep producing blades for now. Uh, which is one reason they were probably able to get this, uh, Oak Tree Capital.
Um, you know, financing, uh, to help them continue operating because they have to make deliveries for anybody that’s got, uh, turbines that they wanna safe harbor before the IRS rules change again, presumably at the end of this calendar year, we’re about. You know, another what, 15 to 20, 20 days away from seeing the first draft of whatever these IRS rules are gonna [00:32:00] be.
I’ve already covered, you know, ad nauseum. I think it’s the 18th or 20th. It’s soon. That’s what I mean. It’s supposed to be, you know, in, within the next few days here, um, that we see a first draft. But just keep in mind that a first draft is not the adoption of the rules. So we’re. We’re expecting that the final rules will be fully adopted by the end of the year.
If you haven’t safe harbored under the current rules, you need to do it now. That’s by the way, why Vestas just announced a 950 megawatt project in the us. Uh, they didn’t say who. Although if you want the details, contact us, uh, Intel store. We know. Uh. So, you know, the, but the reality is anybody that needs to safe harbor turbines needs TPI, particularly ge or even Nordex if they’re, if they’re, you know, getting some of these blades from Mexico, uh, now that most of their, their quality issues I think have been worked out.
Allen Hall: That’s gonna do it for this week’s Uptime Wind Energy podcast. Thanks for joining us. Check out [00:33:00] our uptime tech news where we talk about these subjects and a whole bunch more every week. It’s free. Just Google uptime tech news and you’ll get there. So we will see you next week here on the Uptime Wind Energy Podcast.
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Sunrez Prepreg Cuts Blade Repairs to Minutes
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Sunrez Prepreg Cuts Blade Repairs to Minutes
Bret Tollgaard from Sunrez joins to discuss UV-curing prepreg that cuts blade repair time by up to 90% and has recently recieved OEM approval.
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Allen Hall: Brett, welcome back to the program.
Bret Tollgaard: Thanks for having me again.
Allen Hall: So a lot’s happening at sunrise at the moment. Uh, there’s, uh, activity with sunrise materials on a lot of blades this year.
Over the last couple of years actually, ISPs, operators, OEMs, are realizing that UV curing is a huge advantage.
Bret Tollgaard: Turns out there’s a lot of value added, uh, to the entire process when utilizing UV cure, uh, pre-req.
Allen Hall: So the, the pre pres are, have been available for a couple of years. The qualification though was always the concern.
Has the OEM qualified this material? Are they gonna give you the blessing? Does this show up in the manual? If I call the OEM, are they gonna say they have talked to you guys? A lot of those hurdles have been cleared at this point.
Bret Tollgaard: Yeah, great question. And we are happy to announce that we have finally been approved by a large OEM for use on the epoxy blade for now all general kind of repairs.
We have several more OEMs that have already passed their phase one mechanical testing, and we’re iterating through now [00:01:00] their, uh, secondary and tertiary kind of tests. And so we do expect to be fully qualified by several OEMs before the end of the year, which should make the ISPs integration and utilization of our materials much, much easier.
Allen Hall: So the, the, the problem you’re solving is repairs in the field for the most part, or sometimes in the factory. Mm-hmm. But a lot of times in the field that those repairs. It happened quite a bit. They’re the same repair, the same area, the same kind of thing over and over and over again. And wetting out fabric on site takes time.
Particularly if you’re using standard materials, you have to bag it. You have to apply heat in some cases to get it to kick, and then you have to wait several hours for it to cure. So in the repair cycle time, most of your time is waiting.
Bret Tollgaard: It sure is. Uh, and on top of all that, we all know that there aren’t enough technicians in this industry to even do all the repairs, uh, that would like to be done.
Yeah. And so to really kind of streamline all of that, [00:02:00] uh, we’ve rolled out a couple of new things and we’ve had a lot more interest in some pre consolidated preki patches for customers. Uh, if a particular blade model has an issue that is a standardized kind of repair. We’re actually now building custom prepregs, or we will build the appropriate width length, stack it, consolidate it, uh, wrap it between our films.
So then all the customer has to do when they get on site is, uh, you know, do do the appropriate surface prep. Scarfing, apply a little bit of our UV surface primer to the backside of that patch. But now they can go up tower, single peel, stick, roll out, and then they’re cured.
Allen Hall: And that’s a. How many hours of saving is that?
It’s gotta be like six, 12 hours of saving, of, of
Bret Tollgaard: labor. It’s upwards of 80 to 90% of the labor that’s gonna actually need to be done to apply that. Otherwise, and then same thing too. We’ve had a couple instances where we took a several day repair down to one, to two to three hours. And these are multi-meter long repairs that were fast tracked because we pre consolidated preki [00:03:00] everything.
Some were in flat sheet forms, some were much longer on rolls, where you’re actually then rolling out with a team. Um, and so we’ve been able to demonstrate several times, uh, over the last 12 months, uh, the, the value that a UV cure preprint.
Allen Hall: Well, sure, because that, that would make sense. The issue about wetting out fabric in the field you just done in the back of a trailer or something, somewhere like that.
Usually it is, it’s that you’re never really sure that you got the fabric wetted out. The experienced technicians always feel like, have done it enough that they get very consistent results. But as you mentioned, getting technicians is hard and, and there’s so many repairs to do. So you’re doing those wetting out composite things takes practice and skill.
Just buying it, preki it, where you have control over it. And you guys sell to the military all the time. So that, and you’re, are you ass 91 qualified yet? You’re in the midst of that?
Bret Tollgaard: So we, I mean, a, we just got ISO certified, uh, at the end of last year in December. So our [00:04:00] QMS system and everything like that’s up to date, that’s huge.
Another big qualification for the OEMs that want to see, you know, true quality and output.
Allen Hall: That’s it. I, if I’m gonna buy a preki patch, so, uh, uh, that would make sense to me, knowing that. There’s a lot of rigor as a quality system. So when I get out the the site and I open that package, I know what’s inside of it every single time.
Bret Tollgaard: Well, and that’s just it. And like we got qualified based on the materials that we can provide and the testing that’s being done in real world situations when you’re wetting out by hand and you’re vacuum backing and you’re trying to cure. It is a little bit of an art form when you’re doing that. It is, and you might think you have a great laminate, you got void content, or you haven’t properly went out that glass ’cause humidity or the way the glass was stored or it was exposed.
The sizing and the resin don’t really bite. Well. You might think you have a great repair, but you might be prematurely failing as well after X cycles and fatigue. Uh, simply because it’s not as easy to, to truly do. Right? And so having the [00:05:00] pre-wet, uh, pre impregnated glass really goes a long way for the quality, uh, and the consistency from repair to repair.
Allen Hall: Well, even just the length of the season to do repairs is a huge issue. I, I know I’ve had some discussions this week about opening the season up a little bit, and some of the ISPs have said, Hey, we we’re pretty much working year round at this point. We’re, we’ll go to California. We’ll go to Southern Texas.
We’ll work those situations. ’cause the weather’s decent, but with the sunrise material, the temperature doesn’t matter.
Bret Tollgaard: Correct. And I was actually just speaking to someone maybe half hour ago who came by and was talking about repairs that they had to do in Vermont, uh, in December. They could only do two layers of an epoxy repair at a time because of the amount of the temperature.
Allen Hall: Yeah.
Bret Tollgaard: Whereas you could go through, apply a six or an eight layer pre-reg cure it in 20 minutes. Uh, you know, throughout that entire length that he had and you would’ve been done. That’s, and so it took several days to do a single repair that could have been done in sub one hour with our material.
Allen Hall: I know where those wind turbines are.
[00:06:00] They weren’t very far from, we used to live, so I understand that temperature, once you hit about November up in Vermont, it’s over for a lot of, uh, standard epoxy materials and cures, it is just not warm enough.
Bret Tollgaard: Yeah, we, we’ve literally had repairs done with our materials at negative 20 Fahrenheit. That were supposed to be temporary repairs.
They were installed four or five years ago. Uh, and they’re still active, perfectly done patches that haven’t needed to be replaced yet. So,
Allen Hall: so, because the magic ingredient is you’re adding UV to a, a chemistry where the UV kicks it off. Correct. Basically, so you’re, it’s not activated until it’s hit with uv.
You hit it with uv that starts a chemical process, but it doesn’t rely on external heat. To cure
Bret Tollgaard: exactly. It, it is a true single component system, whether it’s in the liquid pre preg, the thickened, uh, the thickened putties that we sell, or even the hand lamination and effusion resin. It’s doped with a, a variety of different food initiators and packages based on the type of light that’s [00:07:00] being, uh, used to, to cure it.
But it will truly stay dormant until it’s exposed to UV light. And so we’ve been able to formulate systems over the last 40 years of our company’s history that provide an incredibly long shelf life. Don’t prematurely gel, don’t prematurely, uh, you know, erode in the packaging, all those
Allen Hall: things.
Bret Tollgaard: Exactly.
Like we’ve been at this for a really long time. We’ve been able to do literally decades of r and d to develop out systems. Uh, and that’s why we’ve been able to come to this market with some materials that truly just haven’t been able to be seen, uh, delivered and installed and cured the way that we can do it.
Allen Hall: Well, I think that’s a huge thing, the, the shelf life.
Bret Tollgaard: Mm-hmm.
Allen Hall: You talk to a lot of. Operators, ISPs that buy materials that do have an expiration date or they gotta keep in a freezer and all those little handling things.
Bret Tollgaard: Yep.
Allen Hall: Sunrise gets rid of all of that. And because how many times have you heard of an is SP saying, oh, we had a throwaway material at the end of the season because it expired.
Bret Tollgaard: Oh, tremendously
Allen Hall: amount of, hundred of thousands of dollars of material, [00:08:00]
Bret Tollgaard: and I would probably even argue, say, millions of dollars over the course of the year gets, gets thrown out simply because of the expiration date. Um, we are so confident in our materials. Uh, and the distributors and stuff that we use, we can also recertify material now, most of the time it’s gonna get consumed within 12 months Sure.
Going into this kind of industry.
Allen Hall: Yeah.
Bret Tollgaard: Um, but there have been several times where we’ve actually had some of that material sent back to us. We’ll test and analyze it, make sure it’s curing the way it is, give it another six months shelf, uh, service life.
Allen Hall: Sure.
Bret Tollgaard: Um, and so you’re good to go on that front
Allen Hall: too.
Yeah. So if you make the spend to, to move to sun, you have time to use it.
Bret Tollgaard: Yes.
Allen Hall: So if it snows early or whatever’s going on at that site where you can’t get access anymore, you just wait till the spring comes and you’re still good with the same material. You don’t have to re-buy it.
Bret Tollgaard: Exactly. And with no special storage requirements, like you mentioned, no frozen oven or frozen freezer, excuse me, uh, or certain temperature windows that has to be stored in, uh, it allows the operators and the technicians, you know, a lot more latitude of how things actually get
Allen Hall: done.
And, and so if. When we [00:09:00] think about UV materials, the, the questions always pop up, like, how thick of a laminate can you do and still illuminate with the UV light? And make sure you curate I I, because you’re showing some samples here. These are,
Bret Tollgaard: yeah.
Allen Hall: Quarter inch or more,
Bret Tollgaard: correct. So
Allen Hall: thick samples. How did you cure these?
Bret Tollgaard: So that was cured with the lamp that we’ve got right here, which are standard issued light, sold a couple hundred into this space already. Um, that’s 10 layers of a thousand GSM unidirectional fiber. Whoa. This other one is, uh, 10 layers of, of a biox. 800 fiber.
Allen Hall: Okay.
Bret Tollgaard: Uh, those were cured in six minutes. So you can Six
Allen Hall: minutes.
Bret Tollgaard: Six minutes.
Allen Hall: What would it take to do this in a standard epoxy form?
Bret Tollgaard: Oh, hours,
Allen Hall: eight hours maybe?
Bret Tollgaard: Yeah. About for, for the, for the post cure required to get the TGS that they need in the wind space, right? Absolutely. And so yeah, we can do that in true minutes. And it’s pre impregnated. You simply cut it to shape and you’re ready to rock.
Allen Hall: And it looks great when you’re done, mean the, the surface finish is really good. I know sometimes with the epoxies, particularly if they get ’em wetted out, it doesn’t. It [00:10:00] doesn’t have that kind of like finished look to it.
Bret Tollgaard: Exactly. And the way that we provide, uh, for our standard, uh, you know, pre pprs are in between films and so if you cure with that film, you get a nice, clean, glossy surface tack free.
But as more and more people go to the pre consolidation method down tower, so even if they buy our standard prereg sheets or rolls, they’re preki down tower, you can also then just apply a pre, uh, a peel ply to that top film. Oh, sure. So if you wet out a peel ply and then you build your laminate over the top.
Put the primer and the black film over when they actually get that up on tower, they can then just remove that fuel ply and go straight to Sandy or uh, uh, painting and they’re ready to rock.
Allen Hall: Wow. Okay. That’s, that’s impressive. If you think about the thousands and thousands of hours you’ll save in a season.
Where you could be fixing another blade, but you’re just waiting for the res, the cure,
Bret Tollgaard: and that’s just it. When you’re saving the amount of labor and the amount of time, and it’s not just one technician, it’s their entire team that is saving that time. Sure. And can move on to the next [00:11:00] repair and the next process.
Allen Hall: So one of the questions I get asked all the time, like, okay, great, this UV material sounds like space, age stuff. It must cost a fortune. And the answer is no. It doesn’t cost a fortune. It’s very price competitive.
Bret Tollgaard: It, it really is. And it might be slightly more expensive cost per square foot versus you doing it with glass and resin, but you’re paying for that labor to wait for that thing to cure.
And so you’re still saving 20, 30, 40 plus percent per repair. When you can do it as quickly as we can do it.
Allen Hall: So for ISPs that are out doing blade repairs, you’re actually making more money.
Bret Tollgaard: You are making more money, you are saving more money. That same group and band of technicians you have are doing more repairs in a faster amount of time.
So as you are charging per repair, per blade, per turbine, whatever that might be, uh, you’re walking away with more money and you can still pass that on to the owner operators, uh, by getting their turbines up and spinning and making them more money.
Allen Hall: Right. And that’s what happens now. You see in today’s world, companies ISPs that are proposing [00:12:00] using UV materials versus standard resin systems, the standard residence systems are losing because how much extra time they’re, they’re paying for the technicians to be on site.
Bret Tollgaard: Correct.
Allen Hall: So the, the industry has to move if you wanna be. Competitive at all. As an ISP, you’re gonna have to move to UV materials. You better be calling suns
Bret Tollgaard: very quickly. Well, especially as this last winter has come through, the windows that you have before, bad weather comes in on any given day, ebbs and flows and changes.
But when you can get up, finish a repair, get it spinning, you might finish that work 2, 3, 4 later, uh, days later. But that turbine’s now been spinning for several days, generating money. Uh, and then you can come back up and paint and do whatever kind of cosmetic work over the top of that patch is required.
Allen Hall: So what are the extra tools I need to use Sunz in the kits. Do I need a light?
Bret Tollgaard: Not a whole lot. You’re gonna need yourself a light. Okay. You’re gonna need yourself a standard three to six inch, uh, bubble buster roller to actually compact and consolidate. Sure. Uh, that’s really all you need. There’s no vacuum lights.
And you sell the lights. We do, we, [00:13:00] we sell the lights. Um, our distributors also sell the lights, fiberglass and comp one. Uh, so they’re sourced and available, uh, okay. Domestically, but we sell worldwide too. And so, uh, we can handle you wherever you are in the world that you wanna start using uv, uh, materials.
And yeah, we have some standardized, uh, glass, but at the same time, we can pre-reg up to a 50 inch wide roll. Okay, so then it really becomes the limiting factor of how wide, how heavy, uh, of a lamette does a, a technician in the field want to handle?
Allen Hall: Yeah, sure. Okay. In terms of safety, with UV light, you’re gonna be wearing UV glasses,
Bret Tollgaard: some standard safety glasses that are tinted for UV protection.
So they’ll
Allen Hall: look yellow,
Bret Tollgaard: they’ll look a little yellow. They’ve got the shaded gray ones. Sunglasses, honestly do the same.
Allen Hall: Yeah.
Bret Tollgaard: But with a traditional PPE, the technicians would be wearing a tower anyways. Safety glasses, a pair of gloves. You’re good to go. If you’re doing confined space, work on the inside of a, a, a blade, uh, the biggest value now to this generation of material that are getting qualified.
No VOC non [00:14:00] flammable, uh, no haps. And so it’s a much safer material to actually use in those confined spaces as well as
Allen Hall: well ship
Bret Tollgaard: as well as ship it ships unregulated and so you can ship it. Next day air, which a lot of these customers always end. They do. I know that.
Allen Hall: Yeah.
Bret Tollgaard: Um, so next day air, uh, you know, there’s no extra hazmat or dangerous goods shipping for there.
Uh, and same thing with storage conditions. You don’t need a, a flammable cabinet to actually store the material in.
Allen Hall: Yeah.
Bret Tollgaard: Um, so it really opens you up for a lot more opportunities.
Allen Hall: I just solves all kinds of problems.
Bret Tollgaard: It, it really does. And that’s the big value that, you know, the UV materials can provide.
Allen Hall: So. I see the putty material and it comes in these little tubes, squeeze tubes. What are these putties used for?
Bret Tollgaard: So right now, the, the existing putty is really just the same exact thickened, uh, resin that’s in the pre-print.
Allen Hall: Okay.
Bret Tollgaard: And it’s worked well. It’s, it’s nice we’re kind of filling some cracks and some faring, some edges and stuff if things need to be feathered in.
But we’ve [00:15:00] been working on this year that we’ll be rolling out very, very soon is a new structural putty. Okay. So we’ll actually have milled fibers in there and components that will make it a much more robust system. And so we’ve been getting more inquiries of, particularly for leading edge rehabilitation.
Where Cat three, cat four, even cat five kind of damage, you need to start filling and profiling before any kind of over laminates can really be done properly. And so we’re working on, uh, rolling that out here very, very soon. Um, and so that will, I think, solve a couple of needs, um, for the wind market. Uh, and then in addition to some new products that we’re rolling out, uh, is gonna be the LEP system that we’re been working on.
Uh, the rain erosion testing showed some pretty good results. But we’re buying some new equipment to make a truly void free, air free system that we’re gonna it, uh, probably submit end of April, beginning of May for the next round, that we expect to have some very, very good, uh, duration and weather ability with,
Allen Hall: because it’s all about speed,
Bret Tollgaard: it’s durability.
Allen Hall: All about e
Bret Tollgaard: Exactly. And ease of use by someone in the [00:16:00] field. Yeah. Or OEMs on, you know, in the manufacturing plant. Um, there has yet, in my opinion, to be a true winner in the LEP space. That is just the right answer. And so by applying our materials with the really high abrasion resistance that we expect this to have and be as simple to do as it really appeal, stick and cure, um, we think it’s gonna be a bit of a game changer in this industry.
Allen Hall: Well, all the sunrise materials, once they’re cured, are sandal
Bret Tollgaard: correct.
Allen Hall: And I think that’s one of the things about some of the other systems, I always worry about them like, alright, they can do the work today, but tomorrow I have to come back and touch it again. Do I have a problem? Well, and the sun rests stuff is at least my playing around with it has been really easy to use.
It’s, it’s. Uh, things that I had seen maybe 20 years ago in the aerospace market that have they thought about using the material not only [00:17:00] in the factory, but outside the factory. How easy is it to adapt to, how easy to, to paint, to all those little nuances that come up? When you’re out working in the field and trying to do some very difficult work, uh, the sunroom material is ready to go, easy to use and checks all the boxes, all those little nuances, like it’s cold outside, it’s wet outside.
Uh, it’s, it’s hot outside, right? It’s all those things that, that stop ISPs or OEMs from being super efficient. All those parameters start to get washed away. That’s the game changer and the price point is right. How do. People get a hold of you and learn about the sun rose material. Maybe they, you can buy through fiberglass or through composite one.
Mm-hmm. That’s an easy way to do, just get to play with some samples. But when they want to get into some quantity work, they got a lot of blade repair. They know what they’re doing this summer or out in the fall or this winter come wintertime. How do they get [00:18:00] started? What do they do?
Bret Tollgaard: Well, one of the first things to do is they can reach us through our website.
Um, we’re developing a larger and larger library now for how to videos and install procedures, um, generating SOPs that are, you know, semi, uh, industry specific. But at the same time too, it’s a relatively blanket peel and stick patch, whether it’s a wind turbine blade, a corroded tank, or a pressure pipe. Um, and so yeah, www.suns.com Okay, is gonna be a great way to do it.
Uh, we’re actively building more videos to put on, uh, our YouTube channel as well. Um, and so that’s kind of gonna be the best way to reach out, uh, for us. One of the big things that we’re also pushing for, for 26 is to truly get people, uh, in this, in industry, specifically trained and comfortable using the products.
At the end of the day, it’s a composite, it’s a pre impregnated sheet. It’s not difficult, but there are some tips and tricks that really make the, the use case. Uh, the install process a lot easier.
Allen Hall: Sure.
Bret Tollgaard: Uh, and so just making sure that people are, are caught up on the latest and greatest on the training techniques will [00:19:00] go a long way too.
Allen Hall: Yeah. It’s only as good as the technician that applies it
Bret Tollgaard: e Exactly.
Allen Hall: Yeah. That’s great. Uh, it’s great all the things you guys are doing, you’re really changing the industry. In a positive way, making repairs faster, uh, more efficient, getting those turbines running. It’s always sad when you see turbines down with something that I know you guys could fix with sun.
Uh, but it does happen, so I, I need the ISPs to reach out and start calling Sun and getting in place because the OEMs are blessing your material. ISPs that are using it are winning contracts. It’s time to make the phone call to Sun Rez. Go to the website, check out all the details there. If you wanna play with your material, get ahold of fiberglass or composite one just.
Order it overnight. It’ll come overnight and you can play with it. And, and once you, once you realize what that material is, you’ll want to call Brett and get started.
Bret Tollgaard: A hundred percent appreciate the time.
Allen Hall: Yeah. Thanks Brett, for being on the podcast. I, I love talking to you guys because you have such cool material.
Bret Tollgaard: Yeah, no, we’re looking, uh, forward to continuing to innovate, uh, really make this, uh, material [00:20:00] splash in this industry.
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