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What refurbishment and recycling do
Refurbishment aims to return a robot, controller or component to service through inspection, repair, replacement of parts, testing or upgrades. Recycling instead recovers materials or usable components when continued operation is not viable. They are different routes, not necessarily competing all-or-nothing choices: a provider may refurbish reusable equipment and send the rest to a recycling partner.
ABB describes a circular-services portfolio that includes repair, parts, upgrades, retrofits, buy-back, remanufacturing, refurbishment, reuse and recycling. KUKA describes refurbishment and retrofit, buy-back and resale, and recovery of usable parts from robots and controllers no longer suitable for upgrading. These are service options to investigate, not evidence that a particular service is available in every region or for every robot model. ABB robot remanufacturing; ABB circular services; KUKA circular services
When refurbishment is the better fit
Consider refurbishment if the robot’s condition and supported configuration can satisfy the task it will perform, and if the expected service life justifies the work. The decision depends on the whole supported system, not only the arm: controller, software, parts supply, integration needs and service access can determine whether a technically repairable robot is useful in production.
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- The robot can meet the application’s required payload, reach, accuracy, duty cycle and safety requirements after the proposed work.
- The controller, software and interfaces are compatible with the production line and remain supportable.
- The provider can document the inspection, work performed and functional tests, and explain the warranty and its exclusions.
- The total cost and expected remaining service life make sense compared with alternatives for this application.
ABB says its remanufactured robots are inspected and undergo a minimum 16-hour functional test, and that ABB-remanufactured robots and spare parts have a minimum 12-month warranty. Those terms describe ABB’s certified offering; they should not be assumed for other providers or every used robot. ABB remanufacturing service details
When recycling is the better fit
Recycling is appropriate when a credible assessment finds that the robot cannot be returned to safe, reliable service at a reasonable cost, or when critical parts, software or support are unavailable. It may also be the practical route for components that remain after a refurbishment project but cannot be reused.
Ask the provider what will be reused, what will be recycled, who handles each stream and what evidence of material handling is available. Do not treat the label “recycling” as proof that every part is recovered or that a specific environmental outcome has been achieved; request details about the actual route for the asset.
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How to compare environmental impact and cost
There is no general robot-specific head-to-head evidence here proving refurbishment beats recycling on cost or total lifecycle impact. The comparison depends on the robot’s condition, the work required, transport, replacement parts, operating life after refurbishment, the recycling route and what new production or disposal is displaced. Compare options using the same system boundary and assumptions for the application.
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Repair common Windows errors and clear accumulated junk for a smoother, more stable PC - no reinstall needed.Free scan · no reinstallABB states that refurbishing a robot produces 75% less CO2 than producing a new robot. This is ABB’s company claim about refurbishment versus new production—not a comparison of refurbishment with recycling—and the service page does not provide a publication date or methodology for the figure. ABB also states that 60–80% of a robot can be reused, with the remainder sent to certified recycling partners. Treat that as ABB’s stated program figure, not a universal or independently audited reuse rate. ABB robot remanufacturing
A 2023 study by Jia and co-authors assessed one industrial-robot remanufacturing process using a gate-to-gate lifecycle boundary and one iSNM remanufactured robot as its functional unit. In that model, fine particulate matter formation, human non-carcinogenic toxicity and global warming together accounted for 95% of reported environmental impacts; copper and aluminum contributed 42.5% and 37.6%, respectively. These are results for that study and model, not general rates, a full-lifecycle assessment, or a direct refurbishment-versus-recycling comparison. Jia et al., 2023 study
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- Genuine OEM replacement part
- Robot Coupe is the foodservice industry leader in the development and refinement of food processors
- Use genuine OEM parts for safety, reliability, and optimal performance
- Approved by original equipment manufacturer (OEM)
- Intended only for designed and specified use
The UN Environment Programme’s International Resource Panel describes remanufacturing, refurbishment, repair and direct reuse as value-retention processes with potential environmental, social and economic benefits, alongside barriers to scaling them. That broad framing does not determine which route is best for a specific robot. UNEP International Resource Panel report
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.A practical decision process
- Define the production requirement. Record the task, payload, reach, accuracy, cycle time, safety needs and integration constraints the robot must meet.
- Get a condition assessment. Ask for findings on the manipulator, controller and relevant peripherals, including parts that need repair or replacement and any risks that could prevent reliable operation.
- Verify support and compatibility. Confirm the exact controller and software versions, supported parts, service availability and compatibility with the intended line.
- Request refurbishment evidence. Obtain the scope of work, inspection and test records, acceptance criteria, warranty duration and coverage, and any exclusions. Ask whether testing demonstrates the required production performance.
- Compare complete options. Request itemized refurbishment and recycling costs, expected service life, transport and handling, residual value, and the destination of components and materials. If comparing against a new robot, use the same production requirements and lifecycle boundary.
- Choose a route for each part. Return serviceable equipment to use, and specify recycling or other documented handling for components that cannot reasonably be reused.
What ABB’s published program figures do—and do not—show
ABB reports more than 12,000 robots remanufactured globally, six global remanufacturing and workshop repair centers, and around 250 robots taken back per year. The service page does not date these operational counts, so they should be read as ABB-reported figures rather than current, independently verified market statistics. They indicate the scope ABB describes for its program; they do not establish local availability or prove that refurbishment is the best option for a particular asset. ABB robot remanufacturing
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