Case Study: 200 Motors Sourced and Delivered DDP Tarragona in 6 Weeks
In September 2025, a cement plant in the Tarragona region of Spain initiated an emergency procurement programme following a failure analysis report that identified 200 motors across the raw mill, kiln, and cement mill sections as overdue for replacement. The motors ranged from 3 kW to 55 kW and had accumulated between 60,000 and 90,000 operating hours each — approximately double the manufacturer-rated service life for IE1-class units installed in 2004–2007. The plant's procurement team contacted INDASTRA with a requirement to deliver all 200 replacement units DDP to the plant gate within six weeks.
The Challenge: 200 Motors, 14 Different Frame-Pole Combinations, 6 Weeks
The replacement scope was not a single motor type in large volume — it was 14 distinct motor specifications spread across the 3 kW to 55 kW range, with a mix of B3 and B5 mounting configurations, voltage ratings of both 400V and 690V (the plant operates dual-voltage sections), and three duty-critical units requiring ATEX Zone 2 certification for installation in the kiln area. The plant's engineering team provided motor nameplates and, where available, manufacturer type codes for all 200 units.
Sourcing Strategy: Three EU Manufacturers in Parallel
INDASTRA's sourcing team assessed available stock across its European supplier network and determined that no single manufacturer could fill the full scope within the six-week constraint. Three manufacturers were engaged in parallel:
WEG (European distribution centre, Rotterdam)
WEG's Rotterdam stock covered 112 of the 200 units — specifically the B3 foot-mounted units from 3 kW to 22 kW in both 400V and 690V. WEG W22 IE3 motors in IEC frames 100 to 180 were available from warehouse stock with a 5–7 day delivery window. The W22 series matched the IEC frame dimensions of the failed Siemens 1LA5 and ABB M2AA units being replaced, requiring no mounting base modification.
Leroy-Somer (France, IMI region warehouse)
Leroy-Somer supplied 54 units in the 30 kW to 55 kW range, B5 flange mount, 4-pole. The LS IE3 series was selected for its dimensional compatibility with the existing equipment flanges — Leroy-Somer IEC B5 flanges comply with IEC 60072-1 and matched the original mounting without re-machining. Delivery from France to Tarragona: 8 working days by road freight.
Gamak (Turkey, EU Customs Union stock)
The three ATEX Zone 2 units (Ex e, IIC, T3, 11 kW and 22 kW) and 31 additional units in frame sizes not held in Western European stock were sourced from Gamak in Turkey. Gamak's ATEX-certified GMY-Ex series matches the required IEC frames and carries CE marking with DNV GL notified body certification. Delivery from Turkey to Spain under EU Customs Union terms: 9 working days.
Documentation Package
Spanish cement plants are subject to RITE (Spain's Regulation of Thermal Installations) and EU Regulation 2019/1781 compliance audits. For this project, INDASTRA compiled a single documentation package for all 200 units covering:
- CE Declarations of Conformity (per unit type, referencing Regulation 2019/1781)
- IE3 efficiency test certificates traceable to IEC 60034-2-1
- ATEX certificates from DNV GL for the three Ex-rated units
- Dimensional drawings in PDF and DXF format for all 14 motor types
- Packing lists and CMR transport documents for customs and insurance purposes
The documentation package was delivered electronically to the plant's engineering office 48 hours before the first physical delivery arrived, allowing the maintenance team to pre-plan installation sequences.
Delivery Timeline
| Supplier | Units | Dispatch date | DDP Tarragona arrival |
|---|---|---|---|
| WEG (Rotterdam) | 112 | Day 6 after PO | Day 11 |
| Leroy-Somer (France) | 54 | Day 9 after PO | Day 17 |
| Gamak (Turkey) | 34 | Day 12 after PO | Day 21 |
All 200 units arrived at the plant within 21 calendar days of the purchase order, well within the six-week requirement. The plant completed installation and recommissioning of all 200 motors by week five, and the planned kiln maintenance shutdown was met without delay.
Post-Installation Observations
The plant's electrical maintenance manager reported that incoming inspection of all 200 units (visual, IR insulation test at 1 kV, no-load run) passed without rejection. Three WEG units showed minor paint damage from transit but no mechanical or electrical defects. The ATEX units were inspected by a Zone 2 competent person per IEC 60079-17 before energising.
The cement plant has since included INDASTRA on its approved vendor list for motor procurement, with a standing blanket order arrangement for the most-common IEC frame sizes used across the facility.
For emergency motor sourcing requirements across the EU, Turkey and MEA — including DDP delivery, ATEX certification, and complete compliance documentation — contact INDASTRA's procurement team. Standard lead times and available stock for the most common IEC frame sizes are listed in the motor catalogue.