Capital Goods Machine Conserving Resources Starts With the Machinery

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FAULHABER Drive Systems

Taiwan Machine Tool & Accessory Builders' Association (TMBA)

Wuxi InfiMotion Technology Co., Ltd.

In the discourse surrounding sustainability and the circular economy, the focus is usually on consumer goods: recyclable packaging, bio-based materials and textile recycling dominate the debate. However, resource conservation starts much earlier—in the machinery. After all, those who maintain, modernize and use machines over the long term are making an effective contribution to the circular economy.

Machines are the key levers for a more sustainable use of energy and raw materials: they are among the most resource-intensive capital goods in industry, both in terms of production and disposal—even though they are generally designed for decades of use. This is precisely where a rethink is needed: Extending the service life of machines not only makes economic sense, but is also an active contribution to conserving resources. After all, every machine that is used for longer saves valuable raw materials, energy and CO₂.

The 5R Strategy: Sustainability for Capital Goods

In the consumer sector, we often read about the 5Rs principle—Refuse, Reduce, Reuse, Repair, Recycle. It has long been applied there, but the principle can just as easily be applied to capital goods such as industrial machinery: the overriding aim is to minimize the consumption of resources and avoid waste by keeping products in the economic cycle for as long as possible. Instead of replacing machines (Refuse), the focus should be more on reducing the waste of resources (Reduce) through regular maintenance, repair and modernization (Repair). In this way, the machine can also be resold and reused (Reuse). Only irreparable machines should be professionally disposed of for recycling (Recycle).

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However, outdated systems are quickly considered economically unattractive: energy costs are too high, downtimes are too long and CO₂ emissions are too high. In practice, where economic arguments often take precedence over environmental ones, new purchases are therefore still considered more often than maintenance and modernization. However, even machines that are decades old can be brought up to the current state of the art and economic efficiency with little effort.

Appreciate Instead of Replace: Maintenance And Care Conserve Resources

Despite the high acquisition costs for new machines, the mistake is often made of replacing machines after a few years without considering the value of the existing infrastructure. In addition, the purchase of a new machine is seen as a one-off investment and service and maintenance contracts are dismissed as a cost trap. On the contrary: regular care, maintenance and modernization achieve long-term savings and increased service life at low cost. So if you want to invest, you should think ahead.

When purchasing a machine, certain aspects for the maintenance of the capital goods should therefore be taken into account. Modular designs, for example, enable subsequent expansions and needs-based adjustments without having to replace an entire system. This not only saves costs and resources, but also contributes to a flexible and future-proof machine park. Components such as filters or lubrication points that need to be checked regularly should be easily accessible so that maintenance and servicing work can be carried out efficiently. This avoids expensive repairs and breakdowns. The increased availability of the machine leads to higher productivity and therefore greater planning reliability.

Regular maintenance by experts also offers the advantage of becoming aware of modernization potential at an early stage and taking appropriate measures. If the machine no longer meets requirements, it can be resold in a well-maintained condition at a higher price. Used machines purchased by companies such as Deguma remain in the economic cycle thanks to targeted upgrades and are offered for sale again after being adapted to current standards.

The EU Machinery Regulation As A Driver for Modernization

By the time the new EU Machinery Regulation (2023/1230/EU) comes into force in January 2027 at the latest, companies will be forced to address the condition of their machinery. The regulation will create an important basis for Europe-wide safety standards for machinery. It replaces the previous Machinery Directive (2006/42/EC) and introduces new requirements for the safety and energy efficiency of machinery with regard to AI and digital technologies. The new regulation thus provides an additional incentive to not only focus on new purchases, but to consider maintenance and modernization as a long-term strategy; no longer just a question of cost reduction, but of operational capability and legal compliance.

Practical Example: Energy Efficiency through Modernization

Those who invest in modernizing their machines and bringing them up to date can benefit from competitive advantages, long-term savings and increased efficiency. One example of such modernization solutions for rolling mills is the Deguma Efficiency Concept.

A central component of this modernization is the use of torque motors, which offer high energy efficiency, especially at low speeds. They reduce energy consumption by delivering constant torques and thus ensure particularly productive and optimized machine performance, which significantly reduces energy consumption. The reduction in oil consumption as an environmentally harmful operating material thanks to planetary gearboxes also minimizes maintenance costs enormously. In addition to the drives, the control and safety technologies play an equally important role in the modernization of machines for the circular economy, especially with regard to the new MVO. Modern drive controllers and systems such as frequency converters optimize ongoing operation by making adjustments to machine parameters as required and feeding excess energy back into the production process.

In combination with new safety technology, control systems and a general mechanical overhaul, CO₂ emissions, maintenance costs and downtime can be significantly reduced. Energy savings of up to 30 % and up to 80 % lower maintenance costs are realistic—with a service life extension of up to 40 years.

Conclusion: old Machines, New Responsibilities

The circular economy must start with the machines and production facilities—not just with the end products and consumers. Principles such as the 5Rs must be considered and applied universally in order to achieve truly sustainable production. New legislation and regulations such as the new EU Machinery Regulation support this rethink and are increasingly forcing operators to take action.

To achieve this, machines must be viewed as an investment worth preserving and maintained over the long term, regularly serviced and modernized in a targeted manner, otherwise operators are wasting enormous financial potential. This is because the energy efficiency and savings achieved through modernized drive systems, control systems and safety technology not only help to maintain the value of the sale and increase the efficiency and productivity of the systems. Companies that invest in modernization and regular maintenance at an early stage secure ecological and economic benefits and actively contribute to truly sustainable production and a holistic circular economy.

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