Strengthening Transformer Production Through Deep Vertical Integration  

Pennsylvania Transformer Technology (PTT) taps its 1,000,000-square-foot facility, in-house engineering team, and decades of expertise to bring core cutting, insulation fabrication, tank construction, and more under one vertically integrated roof. This end-to-end control reduces supplier dependence, sharpens quality, and speeds delivery across the entire transformer supply chain.

PTT Demonstrates Comprehensive In-House Transformer Production Capabilities

Pennsylvania Transformer Technology (PTT) leverages its expansive manufacturing facilities in Canonsburg, PA and Raeford, NC to control every major stage of transformer production—from core cutting and insulation fabrication to tank construction and vapor-phase drying—ensuring quality, efficiency, and reliability. This deep vertical integration, supported by significant investments in moisture-mitigation technology and facility upgrades, strengthens PTT’s ability to deliver high-performance transformers while reducing dependency on external suppliers.

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PTT RAEFORD NC

PTT Uses Next-Generation GEORG Core Line to Deliver the Industry’s Most Precise Transformer Cores

Key Features and Capabilities of Core Cutting & Stacking Line
  • Transformer cores provide a closed path for the magnetic flux linking the primary and secondary windings.
  • PTT builds “Core Form” Transformers where the windings are outside the core ring.
  • PTT is home to North America’s largest GEORG automatic core cutting and E-Core stacking machine (840 mm).
  • PTT cuts and stacks its cores in-house, ensuring that all cores are properly grounded and built to exact specifications for fit, tightness, and minimum edge burr.
PTT builds “Core Form” Transformers where the windings are outside the core ring.
​PTT operates North America’s largest GEORG automatic core cutting and stacking line

PTT operates North America’s largest GEORG automatic core cutting and stacking line, now enhanced with a new GEORG e-stacker commissioned in January 2025 to produce precision transformer cores with industry-leading burr levels, air gaps, and capacity. Using only high-grade domestic electrical steel, the fully in-house cutting and stacking process ensures exceptionally accurate, tightly built, and properly grounded transformer cores for reliable performance.

Precision-Built Transformer Tanks Engineered for Strength and Long-Term Durability

​PTT’s dedicated 200,000 sq. ft. transformer tank manufacturing shop

PTT’s dedicated 200,000 sq. ft. transformer tank manufacturing shop is fully equipped to cut, form, weld, blast, and finish high-quality transformer and conservator tanks. Combining precision plate-cutting technology, skilled welders, heavy-capacity lifting systems, and a high-pressure blast and paint line, the facility ensures durable, structurally sound, and corrosion-resistant transformer enclosures.

Key Capabilities of PTT’s Transformer Tank Manufacturing Shop
  • Plate steel cut to size—complete with holes and openings—using in-house plasma burn tables
  • Large bending presses used to form tank corners, structural bracing, and custom profiles
  • Certified welders perform full tank welding; welds are ground smooth for a clean finish
  • Completed tanks are sandblasted to SP-5 white metal using a 110-psi blast system
  • Tanks receive high-quality industrial coatings in a controlled paint environment
  • 40-ton overhead crane with dual trolleys enables safe handling of large transformer tanks
  • Dedicated shop layout separate from final assembly for efficient, contamination-free production
Certified welders perform full tank welding; welds are ground smooth for a clean finish

Advanced Vapor-Phase Autoclave Drying for Superior Transformer Moisture Removal and Reliability

Key Features of PTT’s Vapor-Phase Drying and Post-Dry Processing
  • Two high-capacity vapor-phase autoclaves provide deep, uniform drying of core and coil assemblies
  • Upgraded control systems deliver tighter process regulation, improved reliability, and consistent moisture removal
  • Continuous monitoring tracks moisture extraction in real time to verify complete drying
  • Vapor-phase heating penetrates insulation and conductors more effectively than conventional oven drying
  • Assemblies are immediately transferred to a temperature- and humidity-controlled post-dry room to prevent reabsorption of moisture
  • Coils are re-clamped and assemblies tightened for dimensional stability before tanking
  • Final ratio, resistance, and clearance checks are performed to confirm readiness for assembly
A controlled post–vapor-phase room for final tightening and quality checks.
PTT’s Vapor-Phase Drying

PTT’s moisture-mitigation program centers on its two large-capacity vapor-phase autoclaves, which thoroughly dry assembled core and coil packages to ensure superior insulation performance and long-term transformer reliability. A recent multi-million-dollar refurbishment—including upgraded control systems and advanced moisture-monitoring technology—ensures precise, consistent drying, followed by immediate transfer to a controlled post–vapor-phase room for final tightening and quality checks.

Advanced In-House Fabrication of High-Voltage Transformer Insulation

High-voltage transformer insulation

PTT fabricates high-voltage transformer insulation by sourcing premium raw materials and precisely cutting and forming them in-house. Using advanced CNC routing technology, PTT produces core and coil insulation packages with exceptional fit, dielectric performance, and short-circuit strength.

Key Advantages of PTT’s High-Voltage Transformer Insulation Fabrication
  • Uses raw insulation materials from top industry manufacturers
  • In-house cutting, forming, and fabrication for full quality control
  • Precision CNC routers ensure consistent accuracy and tight tolerances
  • Optimized core and coil insulation packages for maximum dielectric capability
  • Engineered strength to withstand mechanical and electrical short-circuit stresses
In-house cutting, forming, and fabrication for full quality control

Controlled Winding and Coil Nesting Environment for Superior Transformer Quality

Key Advantages of PTT’s High-Voltage Transformer Insulation Fabrication
  • Temperature- and humidity-controlled environment to prevent moisture absorption during winding
  • Dedicated coil nesting area for precise sizing, stacking, and alignment of HV and LV coils
  • Coils are clamped and secured following best-practice mechanical stability standards
  • Dimensional checks ensure proper clearances, insulation spacing, and electrical integrity
  • Final quality inspections verify coil geometry, tightness, and readiness for assembly
Dedicated coil nesting area for precise sizing, stacking, and alignment of HV and LV coils
Coils are clamped and secured following best-practice mechanical stability standards

PTT’s expanded, temperature- and humidity-controlled winding room now includes a dedicated coil nesting area designed to maintain optimal environmental conditions for high-voltage transformer winding precision.

This controlled workspace follows industry best practices—ensuring coils are accurately sized, nested, clamped, and quality-verified to support superior electrical performance and long-term reliability.

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Pennsylvania Transformer Technology's Raeford, NC Facility

Key Advantages of PTT’s Raeford, NC Facility

HIGH-BAY EXPANSION
PTT’s Raeford, N.C. transformer production facility was expanded with the addition of a high-bay area with 60 ton crane capacity. This allows PTT to more economically serve the Southeast US market with larger transformer sizes

PAINT BOOTH
With the addition of a new paint booth, transformers built in Raeford are painted to the same high-quality standards used in our Canonsburg, Pa. facility.

Dedicated coil nesting area for precise sizing, stacking, and alignment of HV and LV coils
Coils are clamped and secured following best-practice mechanical stability standards

VAPOR-PHASE PROCESSING
All units built in Raeford, regardless of voltage class, are vapor-phase processed. No shortcuts are taken. Moisture absorption is not left to chance and to outdated drying processes.

FACTORY ACCEPTENCE TEST EQUIPMENT
Investment in power test equipment has created a state-of-the-art test department. The test area boasts new induced/corona measurement, loss measurement, and impulse scope equipment.

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