NEWS

We’re in Orlando this week for O&M, swing by booth 423 and say hello!

#ZephyrWindServices #OMS26 #DoWork

We’re excited to see you all in Orlando, FL next week at O&M. Swing by and say hello, we’re in booth 423

#OMS26 #ZephyrWindServices

We’re One Company with Four Distinct Departments, united by a single mission: to be the best Wind Services Company in the world. Each department plays a critical role in our continued growth and success, and our team members are the driving force behind that growth and success every day. We extend our sincere gratitude to all our team members who go above and beyond to make Zephyr special.

#ZephyrWindServices #ZephyrStrong #DoWork

Right now in the Northern Hemisphere, we’re gaining roughly 2 to 3 minutes of daylight each day. It’s a welcome shift. Each day brings a little more time uptower, a little more time to get the work done safely, and another reminder of how fortunate we are to work in places like this. We’re grateful to be out here, season after season, doing what we love.

#ZephyrWindServices #MajorCorrectives #DoWork

This rotor and hub assembly weighs approximately 43 metric tons, or 94,800 pounds. This substantial component must be lifted to a hub height of nearly 300 feet.

Executing heavy lifts in cold weather presents additional challenges. Meticulous planning, precise execution, and strict adherence to safety protocols are essential when performing lifts of this scale.

#ZephyrWindServices #Repower #SafetyFirst

This week, much of the Upper Midwest, including our Generator shop in Hutchinson, Minnesota, our Drivetrain facility in Muscoda, Wisconsin, and our Repower Outpost in Iowa Falls, Iowa, have been impacted by an unusually strong Arctic air mass. A displaced polar vortex has allowed extremely cold air to move south, keeping temperatures well below seasonal norms. Wind chills across the region have dropped into dangerous territory, creating challenging conditions for residents, equipment, and infrastructure.

These Arctic cold events are more than just uncomfortable. Prolonged extreme temperatures place added strain on infrastructure and increase safety risks, particularly for those working outdoors, where exposure can quickly lead to frostbite or hypothermia.

We hope everyone has stayed safe and taken the time needed to move carefully through these conditions. We are certainly looking forward to warmer weather in the weeks ahead.

#ZephyrWindServices #ArcticBlast #StaySafe

In January, seven years ago, the idea for Zephyr Wind Services was born. Like many businesses, ours started small, but the vision for what we could become has always been big.

One of the founding principles of Zephyr, and a key part of our DNA, is focussing solely on Wind Energy. While constraints might be counter intuitive to building a business, for us, it has always been the key to our success.

Knowing what we don’t do, allows us to be hyper focused on what we DO. It allows us to plan, prepare and evolve the processes and equipment to serve our customers best.

We’re proud of what we’ve built in seven years. We may be biased, but we believe our team is the best in the industry — and we’re excited about where we’ll go in the next seven.

#ZephyrWindServices #LuckyNumber7 #DoWork

Four different perspectives highlighting the same group of all-stars. This team works hard, works safely, and looks out for one another. These images were captured onsite during an active Repower campaign.

#ZephyrWindServices #Repower #DoWork

2025 is one for the books and we’re incredibly grateful for the folks who make Zephyr Wind Services what it is. Looking ahead, we’re excited for all the opportunities to continue learning, growing, and serving our industry and communities. Thank you to everyone who has been part of our journey, here’s to a safe and inspiring 2026!!

#ZephyrWindServices #2025 #DoWork

As we close out the year and look ahead to the holidays, we want to pause and say thank you.

This has been an exciting year for Zephyr Wind Services, and we’re proud to recognize the hard work, dedication, and expertise of our incredible team. Across projects, facilities, and offices, their commitment to safety, quality, and teamwork continues to set the standard and define who we are.

We also recognize that this work doesn’t happen alone. Behind every long day, early morning, and time away from home are families providing support, encouragement, and understanding. Our appreciation extends to the spouses, partners, children, and loved ones who stand behind our people every day.

We’re also grateful to the broader wind energy industry – our customers, partners, and peers. All who challenge us to innovate and to do our best work as we provide critical infrastructure for our country.

Thank you to everyone who has been part of this journey. We wish you a safe, restful, and joyful holiday season, and we look forward to all that lies ahead.

Happy Holidays from us to you,

We’re pleased to share that Tony Vaughn has joined Zephyr Wind Services as Vice President of Operations for our Repower Division.

Tony will work closely with Sean Bonato to support and scale our Repower operations as demand continues to grow across our portfolio.

Tony brings more than 20 years of leadership experience in renewable energy operations, spanning wind, solar, and battery energy storage. Most recently, he served as Senior Manager of Renewables for a major utility, where he oversaw a diverse portfolio of wind, utility-scale solar, and BESS assets totaling more than 1,700 MW. His background includes deep responsibility for safety and environmental compliance, plant performance, maintenance and operations, budgeting, contractor coordination, and multi-site team leadership.

Throughout his career, Tony has led large operational teams, managed complex portfolios, and partnered closely with development and construction groups to deliver reliable, high-performing assets. His leadership style emphasizes safety, practical decision-making, accountability, and team development—all values that align strongly with how Zephyr operates.

Tony’s experience and operational mindset will be a strong complement to our Repower leadership team, and we’re excited to have him on board as we continue to expand this division.

#ZephyrWindServices #DoWork #Repower

This all-star team just completed their 121st drivetrain for an ongoing repower campaign — starting May 1st and reaching 121 on December 11th. It’s a major milestone for the facility and a testament to their craftsmanship, dedication, and hard work; we couldn’t be more proud.

Based in Muscoda, Wisconsin – our Drivetrain Division is purpose-built to support drivetrain assembly, disassembly, refurbishment, and repair for the wind industry.

#ZephyrWindServices #Drivetrain #DoWork

As industries increasingly operate in extreme climate environments, whether frigid winters, high altitude cold zones, or sub zero wind exposed sites, prioritizing worker safety becomes more than a regulatory obligation. It is a critical component of health, performance, and long term operational resilience.

When the body is exposed to sustained cold, it works overtime. Beyond the demands of the job itself, it burns additional calories simply to maintain core temperature. Studies show that during cold exposure, even in the absence of heavy physical activity, the body may increase energy expenditure as it thermoregulates.

Once shivering begins, the calorie burn can be significant. Estimates suggest 100 to 400 calories per hour depending on intensity, body composition, and exposure duration. Over an 8 hour shift in conditions that trigger shivering, this can result in an extra 800 to 3,200 calories burned, on top of normal workload energy demands.

This has several critical implications for employers and EHS professionals:

• Thermal stress acts as a hidden workload. Cold exposure adds metabolic strain, increasing fatigue, reducing cognitive performance, and accelerating energy depletion.
• Workers may require additional breaks, increased caloric intake, and hydration strategies tailored to cold environments.
• Safety planning must include climate adaptation. Proper clothing, warming shelters, shift rotation, and nutrition support are essential to maintaining worker well being.
• Repeated cold stress without mitigation elevates the risk of illness, injury, and diminished morale.

In wind repower and other climate exposed operations, the environment is not just a backdrop. It is a factor that directly affects safety, human resilience, and project success. For all of us responsible for EHS, it is essential to embed climate resilience and human factor planning into our safety strategy, from PPE and hydration to task scheduling and crew support.

Stay safe. Stay warm. Stay prepared.

As we celebrate the Thanksgiving holiday, Zephyr Wind Services extends its gratitude to our team, colleagues, partners, and the broader wind industry for an exceptional year. The hard work, commitment, and professionalism demonstrated every day – on job sites, in the shop, in the office, and across the industry – continue to drive wind energy forward.

Zephyr is grateful for our employees, for the collaboration shared across the industry, and for the meaningful impact this collective effort makes throughout the year.

Wishing everyone and their families a safe, restful, and Happy Thanksgiving.

#ZephyrWindServices #Thanksgiving2025 #BeSafe

Duty. Honor. Country. Saluting the brave men and women who have served our nation.

Wishing you all a safe, spooky and Happy Halloween!

#HappyHalloween #SafetyFirst #ZephyrWindServices

Sometimes you’ve just gotta stop, take in the view, and truly appreciate it all
📸 Chris Anders

#ZephyrWindServices #Repower #AutumnIsTheBest

During a Major Corrective or Repower campaign we obviously can’t control the weather. We can however control our safety culture and mindset. Here at Zephyr we define the safety mindset as a cognitive and behavioral orientation in which our team consistently prioritize risk awareness, hazard recognition, and preventive action in our decision making processes. This culture reflects a proactive attitude toward identifying, assessing, and mitigating potential threats to our team and organizational safety, rather than relying on external enforcements.

The safety mindset encompasses both situational awareness – the ability to perceive and comprehend environmental conditions — and self-regulation, where our team consciously aligns their behavior with safety goals of our organizational standards.

So when the weather windows present – we’re ready to work. Often this is well before sunrise, long after sunset and of course during the heat of the day. No matter what the clock says, we train to be prepared, to be safe, and to watch our for one another.

#ZephyrWindServices #Repower #MajorCorrectives #SafetyFirst

We’re grateful for our hard-working and safety-minded teams, the cooler temps and the crisp mornings. Happy start of Autumn, y’all!
Photos: Chris Anders

#ZephyrWindServices #Repower #AutumnIsTheBest

Zephyr Wind Services was proud to support the 4th Annual MED13L Golf Tournament earlier this September. Thanks to the incredible support of everyone involved, the event achieved its most successful year yet in the fight to find a cure for MED13L.

#GolfingForeACure #MED13LStrong #ZephyrWindServices

On par with Lady Liberty, wider than a 747’s wingspan, and as tall as a 40-story building — this is everyday scale for our Repower group at Zephyr Wind Services. The immense amount of experience, dedication, and precision they bring to the job every day is impressive, to say the least.
Photos: Chris Anders

#ZephyrWindServices #Repower #DoWork

We’re fortunate to have an exceptional EHS team at Zephyr — a group that continually champions the idea of being your brother’s and sister’s keeper, of always watching out for one another.

Under the guidance of Director of EHS Randy Soterhou, and strengthened by leaders Chris Anders, Kannon Dry, and Waylon Bamburg, our team is shaping a culture where speaking up, lending a hand, and looking out for one another are core values of our organization.

At Zephyr, safety is more than a responsibility — it’s one of the most powerful ways we demonstrate respect for our team, our colleagues, and our customers.

#ZephyrWindServices #EHS #SafetyFirst

We’re incredibly grateful for our team and the way you show up every day — working hard, staying safe, and making Zephyr who we are. This Labor Day, we hope you take time to enjoy a well-deserved break.
📸: Chris Anders

#ZephyrWindServices #LaborDay #DreamTeam

Since our grand opening in 2019, our Hutchinson, Minnesota Generator Shop has grown from a single building into a 15-acre, seven building campus purpose-built for the wind industry. This scale enables us to provide full-service wind generator support, including diagnostics, coil manufacturing, reverse engineering, and complete rebuilds. With programs like our Generator Exchange Program, industry-leading VPI process, and cloud-based quality control, we help customers minimize downtime and keep turbines online with faster, more reliable service than traditional service centers. In addition, our dedicated Drivetrain facility, world-class Parts department, and hardworking Repower division come together to deliver a responsive and unmatched customer experience in our industry.

#ZephyrWindServices #DoWork #OnlyTheBest

Seen from the nacelle, a drivetrain is being lowered to awaiting transportation. All four Zephyr Divisions – Repower, Drivetrain, Parts and Generators work in symphony to remanufacture, refurbish and procure all equipment on Repower and Major Corrective campaigns. This synergy has earned some big fans.
Photo: Corey Heinemann

#ZephyrWindServices #MajorCorrective #DoWork

Another stunning morning as seen on a recent commute to an ongoing Repower project. A big perk of our work is the many incredible sunrises, sunsets and vistas we get the opportunity to enjoy. Photo: Chris Anders

#ZephyrWindServices #DoWork #Heartland

We’re excited to share some great news from the Zephyr Wind Services family!

Carlin Carlson, daughter of our Repower Director of Sales, Dustin Carlson, recently traveled to Italy to represent Team USA at the 2025 International Sun League Series Tournament. Carlin and her team played their hearts out and brought home an impressive 3rd place finish!

We’re incredibly proud to support Carlin and celebrate this amazing achievement with the Carlson family. Way to go, Carlin!

#ZephyrWindServices #TeamUSA #GoTeamZephyr

We’re beyond pleased to announce the promotion of John VanderKuur to Chief Operating Officer!

Since joining Zephyr in 2020 as Director of Engineering, John has brought a wealth of technical expertise and leadership experience. He has been instrumental in shaping our engineering standards and operational excellence—from implementing the EASA Quality Management System to launching Zephyr University for employee and customer training. His efforts have consistently driven innovation, enhanced safety, and improved reliability across our operations.

John’s extensive background spans more than three decades across the renewable energy and automotive sectors—as well as service in the U.S. Navy. His experience and nearly unlimited enthusiasm position him exceptionally well to lead Zephyr through our continued growth.

Please join us in congratulating John on this well-deserved and hard earned promotion. Happy Monday, JV!

Some of our greatest breakthroughs and innovations have come from looking at a process from a different perspective — turning it upside down, so to speak. This mindset, from a company culture standpoint, is something we’re particularly excited about at Zephyr.

#ZephyrWindServices #ProblemSolving #ProcessImprovement

Hard to believe we’re nearly halfway through summer – it’s been a whirlwind of always working in a safety-first mindset, bringing our A-game to every task and of course – chowing down on plenty of tasty BBQ and sweet corn

#SafetyFirst #ZephyWindServices #DoWork

Wishing a safe and relaxing Fourth of July to all our Team, Customers and Colleagues.

#FourthOfJuly #ZephyrWindServices

Rolling into one of our favorite weeks of the year

#ZephyrWindServices #Summer #DoWork

Various stages and perspectives of an ongoing Repower project captured through the lens of Zephyr Wind Repower Project Manager, Terry Burgess

#ZephyrWindServices #Repower #TeamWork

Our specialized divisions focus exclusively on the core systems of wind turbines. Our Parts team manages complex component needs with precision, while our Generator, Drivetrain, and Repower branches bring deep, dedicated expertise to their respective areas. What sets us apart is our sole focus on the wind industry. This clarity of purpose enables us to deliver consistent, high-quality results—and it’s a source of pride across our organization.

Photo by Repower Technical Advisor Luke Wharton, taken during an ongoing Repower project.

#ZephyrWindServices #DreamTeam #DoWork

Several of the Many Perspectives on an Ongoing Major Corrective Exchange Campaign. All photos from Field Service Manager Corey Heinemann.

#ZephyrWindServices #MCE #MajorCorrectives

Another great photo and update from the field by Repower Director of Sales, Dustin Carlson.

#ZephyrWindServices #Repower #DoWork

On Memorial Day, we pause to honor the men and women who gave their lives in service to our country. Their courage and commitment to duty, honor, and country will never be forgotten.

13 great reasons to swing by Booth 1338 at CleanPower in Phoenix. We’re in full swing and having an excellent show. Stop by, say hello, and see what’s new at Zephyr Wind Services.

#ZephyrWindServices #CleanPower25 #Booth1338

Zephyr Wind Services is proud to support the Fourth Annual ACP Golf Tournament as a contributing sponsor. Presented by RNWBL, this year’s tournament will take place today at the Whirlwind Golf Club at Wild Horse Pass in Chandler, Arizona as we kick off the annual ACP CleanPower tradeshow.

We look forward to a great day on the course!

#ZephyrWindServices #CleanPower25 #RNWBLacp2025Golf

Slow is smooth, and smooth is just right.

#ZephyrWindServices #Repower #DoWork

Pictured at the front of the room: Director of Engineering John VanderKuur speaking at a recent orientation about our process, safety culture, and commitment to quality. Communication is a key ingredient at Zephyr. Clear expectations and shared understanding form the foundation of our projects.

#ZephyrWindServices #SafetyFirst

April showers bring May Repowers – as recently captured in the heart of the midwest by Field Services Manager Corey Heinemann

#ZephyrWindServices #MajorCorrectives #Repower

Come visit us at Booth 1338 in Phoenix, AZ at CLEANPOWER – May 19th – 22nd, 2025. We’re excited to catch up and connect with you all.

#ZephyrWindServices #Cleanpower2025 #Booth1338

Before any work begins—whether in the field, the shop, or the office—a clear and focused safety brief sets the tone. As demonstrated by our Repower team pictured here, this step is far more than routine; it reflects a core value that keeps everyone aligned, aware of potential risks, and ready to take proactive measures. This disciplined approach reinforces a culture where safety isn’t just a requirement—it’s the foundation of everything we do.

#ZephyrWindServices #DoWork #SafetyFirst

As we kick off the week, it’s always good to remember the fundamentals: work with integrity, be eager to innovate and solve technical challenges, and keep safety at the forefront. Wishing you all a safe, focused, and fulfilling week ahead.

#ZephyrWindServices #DoWork #SafetyFirst

We believe success is in the details. At first glance, it’s just another crisp, clear morning at our Hutchinson, MN Generator facility. But look a little closer, and the Zephyr story starts to reveal itself.

You’ll notice every vehicle backed into its spot — not because it’s easier, but because it’s safer. You’ll see a clean, well-kept campus, snow markers ready for winter maintenance, and pride in our country. You’ll see our president and founder out front, sprinkling deicer — not because anyone asked him to, but because he’s looking out for everyone’s safety. You’ll see enthusiasm, kindness, and mutual respect. Quality at Zephyr starts with the little things — and it ripples through every part of our business.

#ZephyrWindServices #Quality #DoWork

Perhaps we can all agree that sunrise pictures of wind turbines producing energy aren’t unique. What is unique, however, is our culture here at Zephyr. The pride and dedication our team brings to all aspects of our business shine through in how we approach, plan, and execute our projects. Beyond delivering technical excellence, we actively promote a collaborative environment where safety, innovation, and integrity are at the core of everything we do. It’s this commitment—to our customers, to each other, and to the future of our industry—that we’re most proud of.

#ZephyrWindServices #TeamWork

Really starting to green up out there ☘️

#StPatricksDay #ZephyrWindServices #GreenEnergy

70 (of countless) ways our parts division keep you up and running

#ZephyrWindServices #WindParts #OurPartsDivisionRocks

We’re in full stride at O&M in Nashville today, come say hi at booth 728

#OMS25 #ZephyrWindServices #DoWork

We’re proud to announce the promotions of Joel Dreistadt to Vice President of Operations and Kristen Haag to Vice President of Business Development in our Parts Division

Both Joel and Kristen have played instrumental roles in establishing and scaling the division, making it a key driver of growth for Zephyr Wind Services. Their leadership and expertise have strengthened our operations, supply chain management, sales, and customer relationships, positioning us for long-term success in the wind energy industry.

Joel Dreistadt
Since joining Zephyr Wind Parts in 2021 as Senior Manager, Joel has been pivotal in optimizing supply chain efficiency, procurement, logistics, and warehouse operations. His leadership has transformed the division, and in his new role, he will oversee strategic sales growth initiatives and operational excellence.

With over a decade of experience in operations management, Joel previously served as Plant Manager, where he led multimillion-dollar inventory operations and significantly improved efficiency. His ability to build high-performing teams and drive process improvements will continue to strengthen Zephyr Wind Parts’ operational foundation.

Kristen Haag
Since joining Zephyr Wind Services in December 2021 as a Senior Manager, Kristen has played a critical role in expanding the Parts Division. Her expertise in sales and budget forecasting, contract management, procurement, and logistics has positioned Zephyr as a trusted provider of new and reconditioned parts. In her new role, Kristen will lead strategic initiatives to strengthen client relationships and drive market expansion.

With over 15 years of experience in procurement, supply chain management, and business development, Kristen has held multiple leadership roles across the industry. She holds a Bachelor of Arts in Communications and Business from Washington State University and brings deep expertise in international logistics and proposal development.

We are excited for Joel and Kristen as they take on these leadership roles, further enhancing our ability to serve you all in our wind energy industry. Please join us in congratulating them on their well-earned promotions!

#zephyrwindservices #dowork #teamwork

We’re excited to see you all in Nashville, TN next week! We’re at booth 728, come by and say hi!

#OMS25 #ZephyrWindServices

Friday Night Lights!

Another great photo from Repower Director of Sales, Dustin Carlson. Not pictured: the countless hours of preparation, safety planning, weather monitoring, and teamwork that make every operation possible.

Incoming! 15 of us are headed to the O&M + Safety show in Nashville, TN. Swing by booth 728 March 3rd-5th and say hi. We’re excited to see you all!

#ZephyrWindServices #OMS25

What’s Up? At Zephyr, we’re fully dedicated to the wind energy industry. Our four divisions — Generators, Parts, Repower, and Drivetrains all work seamlessly together, making us a unique one stop solution for our customers. By focusing exclusively on wind, we’ve created a company structure that drives innovation and delivers exceptional problem solving for the challenges we face while doing our work. We’re proud of what we’ve built and excited to keep pushing the boundaries of what’s possible.

#DoWork #ZephyrWindServices

Rigged, ready and flying into 2025. Photo by Repower Service Manager Corey Heinemann

At Zephyr Wind Services, our mission is simple: to be a trusted partner for the wind industry by providing reliable, world-class solutions dedicated exclusively to renewables.

That’s why we’re excited to announce our new partnership with Mersen. As a trusted distributor of Mersen brushes Zephyr now offers:

• Reliable stock availability of Mersen’s world-class carbon brushes
• Expert technical support to match the best brush to your generator
• Minimize downtime for your operations

While small, a generator brush plays a critical role in turbine performance. The right brush ensures smooth operation, optimal slip ring protection, and balanced longevity. Learn more about this partnership and how we can support your operations. Reach out to our parts team today!

With safety as our top priority, we embrace the challenges of working in all kinds of weather to get the job done. A blanket of snow and a pitch-black sky are just some of the unique conditions we encounter on the job. A huge thank you to our incredible team for going above and beyond while keeping safety at the forefront. 

We are delighted to announce that Sean Bonato has joined Zephyr Wind Services as the new Vice President of our Repower Division. Sean brings a vast wealth of experience, a passion for innovation, and a proven track record of leadership that will undoubtedly elevate our efforts in this crucial area of our business.

Sean has spent more than 24 years managing and maintaining aircraft systems, combustion engines, wind turbines, and their associated subsystems. His extensive expertise spans leadership roles across complex operations, including his tenure as a Combustion & Wind Turbine Supervisor at Montana Dakota Utilities. In addition to his professional achievements, Sean is a veteran with over 22 years of service, where he honed his skills in team building, strategic planning, and program development.

Beyond his professional credentials, Sean’s collaborative nature and ability to build strong relationships resonate deeply with Zephyr’s values. Having worked alongside members of our team on past projects, Sean has already demonstrated his ability to create win-win scenarios and foster a culture of respect and trust.

As Vice President of the Repower Division, Sean will lead initiatives to enhance our capabilities in the field and between our various divisions, ensuring Zephyr remains at the forefront of innovation in wind energy. We’re thrilled to have him on board and look forward to the impact he will make in shaping the future of our company.

2024 was an incredible year for Zephyr Wind Services, made possible by the hard work of our outstanding team and the trust of our many customers. A heartfelt thank you to everyone who contributed to our success! As we look ahead to 2025, we’re eager to continue innovating and finding new ways to enhance our services and support the wind energy sector.

The longest nights of the year often lead to breathtaking sunrises, like this one captured last week by our repower team deep in the heartland.

Winter landscapes provide striking backdrops for wind energy, reminding us of the incredible environments we get to work in. Wishing everyone a safe and productive season – stay warm and take care out there!

In the United States, wind energy production typically peaks during the winter months, driven by seasonal atmospheric conditions like stronger pressure gradients and powerful jet stream activity. While the exact percentage varies by region and year, wind turbines generally generate 25-30% of their annual energy output between December and February. Here’s to wishing our customers and colleagues a successful and productive peak wind energy season.

This Thanksgiving, we reflect on all we have to be grateful for — especially our incredible team, colleagues, customers, and all our families. Wishing you all a joyful and memorable holiday filled with gratitude and warmth.

At Zephyr Wind Services, precision and reliability are at the core of everything we do. In this video, President Trevor Armstrong and Director of Engineering John VanderKuur explain the critical role of the balance stand in ensuring the smooth operation and longevity of wind turbines. Just like an unbalanced car tire can cause vibrations, an unbalanced rotor in a wind generator produces vibrations that must be absorbed by the machine. To address this, we go above and beyond industry standards, balancing our rotors to ISO Grade 1.0—far superior to the typical ISO Grade 2.5. From the rotor to the fan subassembly and the complete rotor assembly, we meticulously balance each component to achieve unparalleled precision and efficiency.