Thanks to Reman: No case for the scrapheap

Everyone talks about it, but hardly anyone does it! In a nutshell, this is how you could describe the current situation of the circular economy around the world. In the past five years, the number of discussions, debates and articles about the circular economy has almost tripled. In the same period, the rate has fallen from 9.1 to 7.2 percent according to the Circularity Gap Report 2024. In other words, more new material is being consumed worldwide than ever before, while the proportion of recycled material is falling. "More than 90 percent of the global economy follows a linear model of extracting resources, producing, selling, using and then throwing away," says Marc Goldschmidt. "Doesn't it make sense to do much more and ensure that the rate reaches double digits as quickly as possible?"

Marc Goldschmidt is Head of Remanufacturing & Overhaul Technologies at Rolls-Royce's Power Systems division. He has been an advocate of the circular economy for years and has already achieved a great deal. Around 1,500 engines and systems as well as thousands of components are overhauled, repaired or remanufactured in the Rolls-Royce Reman centers every year - and the trend is rising. PowerPacks for railcars in particular, but also mtu Series 2000 and 4000 engines used in trains or gensets, are completely overhauled, fully refurbished and then reused at Rolls-Royce Power Systems in a standardized process.  

"This is not only sustainable, but also economical," explains Marc Goldschmidt, who adds that customers are increasingly asking for CO₂-optimized yet economical products, solutions and manufacturing processes.

Reman plants of Rolls-Royce in Germany and North America

The heart of Rolls-Royce's remanufacturing processes is located in Magdeburg - in addition to a recently expanded plant in North America. In the reman plant, complete mtu engines and systems as well as individual components are reconditioned and reused using standardized processes. More than 40,000 products have already undergone the Reman process there. Between 150 and 250 rail PowerPacks, for example, arrive in Magdeburg every year and leave the plant in as-new condition - ready for another 18,000 hours of operation.

Reman: Industrial refurbishment in a standardized process

The term "reman" (from remanufacturing) refers to the industrial refurbishment of main components and motors. In standardized processes, the systems and engines are first disassembled into their individual parts, cleaned and tested for function and wear. The individual parts are then refurbished, assembled, painted and reassembled with Reman components or new parts. The engines that are reconditioned at the Reman plant in Magdeburg are then as good as new. The high quality is guaranteed by automatic improvements to the engine and strict functional tests, which are subject to the same criteria as for new engines. Therefore, the same warranty conditions apply to a Reman engine as to a new engine.

Attractive for customers: Remanufacturing within 15 days

To keep train downtimes as short as possible for customers, the Magdeburg site has set itself up in such a way that products can be overhauled within a maximum of 15 days. For some Series, Rolls-Royce can also provide replacement PowerPacks or engines, so-called "swing units", before the drive unit is removed. Customers can install these "replacement engines" in their railcars or locomotives and do not have to wait until the first systems have gone through the remanufacturing process. "In this way, we keep downtimes to a minimum for our customers," explains Marc Goldschmidt.  

Rolls-Royce has also established a deposit system to help boost recycling.   This creates financial incentives for the return of used engines by giving customers a credit note, the amount of which depends on the condition of the returned engine.

Netinera has also been relying on Rolls-Royce reman solutions for many years. The company is one of Germany's largest transportation companies and operates local and regional public transport services with buses and trains. Rolls-Royce has already overhauled and remanufactured numerous mtu engines and mtu rail PowerPacks on behalf of Netinera in the past.  

EU wants to strengthen circular economy with action plan

The European Union had already published a corresponding action plan with regard to the circular economy in 2020, which is a central element of the European Green Deal. The plan contains proposals for more sustainable product design and, according to the Commission, aims to reduce waste and strengthen consumer protection - for example through a "right to repair". The aim of the Green Deal, in turn, is to make Europe a climate-neutral continent by 2050.  

Rolls-Royce to further expand reman and overhaul services

Rolls-Royce is also looking to further expand its remanufacturing business and has added a new regional center for remanufacturing and overhaul to its production plant in Aiken, South Carolina. Covering an area of around 6,500 square meters, the new facility will offer tailor-made remanufacturing and overhaul services to meet growing customer demand. But the portfolio is also to be expanded: "We see a lot of potential in the circular economy," says Marc Goldschmidt, who will not lose sight of his goal - to contribute to achieving the double-digit quota with Rolls-Royce.