Unlocking hidden AEP: Turning wind turbine blade protection into long term performance

Leading edge protection has moved from early adoption to proven practice. In 2026 Polytech has been in the market for 10 years with ELLE® starting with our shells in 2016 and today protecting more than 80,000 blades.

Many operating fleets have untapped potential. Most sites and blades are exposed to leading edge erosion and repeated repairs, and turbines slowly move away from the performance they were designed to deliver if not taken care of. As an operator and owner, the balance is always, how costly is it to do nothing vs to quick fix repeatedly or once or twice during lifetime operations. Downtime vs cost vs lost or gained full load production hours.

Aftermarket upgrades are one of the most effective ways to close that gap. By adding durable, field proven protection to critical areas, operators can safeguard blades, stabilize output and reduce unplanned work across the lifetime of the turbine.

From “keep it running” to “keep it performing”

Service strategies often focus on keeping turbines available. That is essential, but availability is only part of the story. If leading edges are worn, surfaces degraded or known weak spots left unaddressed, the turbine is turning without delivering its full potential. Either because it’s curtailed or stopped.

Aftermarket upgrades help add a performance focus to that picture:

• Leading edge protection is applied to the blade to shield it from erosion and harsh weather, helping to preserve the original aerodynamic shape
• Advanced blade protection concepts such as ELLE® are designed to handle demanding erosion environments where standard coatings and paint repairs are not enough
• Targeted retrofit solutions can be used to protect areas that have shown recurring issues in inspections and field data

Instead of simply accepting that older turbines underperform, operators can actively protect and enhance the blades and components that matter most.

Built on a deep understanding of loads and materials

Effective aftermarket concepts are not developed in isolation. They draw on many years of insight into turbine loads, blade structures, materials and real operating environments. The experience behind ELLE® is therefore not theoretical, but grounded in large scale deployment across operating fleets.

That background makes it possible to:

• Place protection where it has the greatest impact on durability and performance
• Match materials and designs to the specific loads that blades experience in operation
• Offer solutions that have already been proven on comparable turbine types and in similar site conditions

This engineering and field-based approach reduces uncertainty and supports more predictable behavior over the lifetime of the upgrade.

Extending asset value across the lifecycle

Wind turbines are expected to operate for decades in environments that are rarely static. Storm patterns, site exposure and operating strategies evolve, and so do the loads acting on blades and components.

By combining long term field experience, material know-how and a detailed understanding of turbine behavior, Polytech aftermarket solutions can:

• Slow down leading edge erosion and reduce the need for repeat repairs
• Support more predictable energy production from aging assets
• Reduce exposure to unplanned blade work or replacement and the costs and risks that come with it

The result is a fleet that is not only kept running but kept closer to its intended performance level throughout its lifetime.

Learn more about our solutions for the aftermarket HERE.