Sustainability along the robot life cycle

Refurbished robot systems help customers take advantage of new functionalities and advanced services while reducing maintenance costs and maximizing return on investment. © ABB

Even sectors that are currently still less automated benefit from the sustainable use of robotics. This is the case in the construction industry, for example, where new solutions are needed that enable sustainable and cost-effective construction. Robot-assisted automation can also help to improve quality and consistency in order to reduce construction waste. By using automation - for example in the prefabrication of entire building modules on the factory floor using robot-assisted 3D printing processes - and digital solutions, construction companies can make their design and manufacturing processes more effective and avoid construction waste right from the start of the project. Prefabrication reduces material consumption by 25 %. Robotics in the design process is also suitable for using raw materials such as glass, cement and steel more efficiently, thereby reducing the_{carbon footprint} of buildings.

Robotics also helps with sustainability in automotive production. ABB's PixelPaint technology, for example, eliminates the need for masking the car body during two-color painting and prevents paint mist. With the innovative inkjet head, no paint is wasted and productivity is accelerated by halving the painting time.

Repair, refurbish, recycle

Until now, sustainability in robotics has often been limited to efficiency gains during operation and the resulting reduction in the use of raw materials and harmful emissions. Sustainability during operation is important, but the end of the life cycle is also crucial. If a robot fails in operation, there are a number of ways to respond sustainably. Many defects that occur in older robot models can be quickly rectified by repair. If the robot can no longer be repaired, manufacturers such as ABB offer to take the products back, for example in exchange for a refurbished device or a product of a newer generation. This is because many robots can be reconditioned for reuse - with a positive effect on the environmental balance: reconditioning a robot produces 75% less_{CO2 than} manufacturing a new robot. Many customers also opt for remanufactured models because their bus and safety technology is not compatible with newer robot models.

Reconditioning follows strict guidelines. At ABB, every robot is inspected according to a precise plan, thoroughly checked and subjected to strict functional tests. If the robot passes, it is put back into circulation with a twelve-month warranty. "We completely remanufacture our robots using the original design plans, specifications and dimensions. This ensures that they offer the same level of quality, performance, durability and safety as a new ABB robot," says Jan Borsky, sales manager of ABB's global repair and remanufacturing centers. "We always have more than 400 used and refurbished robots of various types in stock for sale. The demand for second-life robots is currently so high that more than one robot leaves our factory in Ostrava, Czech Republic, every working day." In automotive manufacturing, almost all robots can be installed in a new production line after reconditioning, and between 10 and 20 % can even be installed a third time. In the last 30 years, ABB has reconditioned over 12,000 robots and put them back on the market.

Sustainability also in demand from customers

Another example is the expansion of an existing production line. If a company wants to expand production, it is easier to add a remanufactured robot of the same generation to the production line. In this way, companies ensure that the robots are compatible with each other. No additional training is required for employees and there is no need to expand the spare parts warehouse. In both cases, opting for remanufactured robots is more cost-effective than converting an entire production line. For customers, the service life of a robot is often less important. It is more about how long spare parts will be available for the respective model.

The network of remanufacturing sites supports customers in recycling used ABB robots. © ABB

However, remanufacturing is not always an option. In these cases, the individual parts of the robots are recycled. Around 95% of a robot is made of material that can be easily recycled. ABB works with certified recycling partners to ensure that the reuse of raw materials is as sustainable as possible.

If robotics manufacturers want to promote sustainability, they should also ensure that they implement the resolution in their own corporate practices. Compared to 2019, ABB has already reduced its_{CO2 emissions} by 76% in 2023. The company has also stopped using fossil fuels to heat its buildings and has switched its vehicle fleet to electric vehicles.

The robotics expert has also equipped its production facility in Shanghai and the reprocessing center in the Czech Republic with solar panels. Geothermal energy is also used at the new Robotic Campus in Sweden. By producing sustainable robots that increase efficiency and reduce environmental impact, ABB is helping customers to break new ground.