Case studies
Sustainability and cost-efficiency are essential for companies striving for long-term success, yet many face the challenge of balancing these two demands.
As market expectations continue to rise and companies are pushed toward substantial investments to keep up, the value of extending the lifecycle of existing equipment is becoming increasingly clear. This shift—from constantly investing in new machinery to instead optimizing current resources—opens the door to innovative solutions that promote both economic and environmental sustainability.
A challenge in the automotive industry: Ageing AGVs in need of new life
Our customer, a leading player in the automotive industry, faced a specific challenge in their effort to achieve both economic and sustainable growth. Two of their TC20-model AGVs, originally implemented in 2001 and later upgraded by us in 2015, had accumulated an impressive 70,000 operating hours. Despite this extensive service life, a carefully planned refurbishment showed that these AGVs could continue to play a central role in the production flow. The refurbishment was not only a cost-effective decision but also a clear demonstration of our commitment to maximizing the value of existing resources in line with modern sustainability principles.
From inspection to optimization
The refurbishment was carried out with meticulous attention to detail, thoroughly reviewing and optimizing components to ensure maximum performance and longevity. The step-by-step process included:
- A thorough inspection of the electrical and mechanical systems
- Restoration of missing components such as main switches, fuses, terminals, cabling, drive brakes, and drive servos
- Replacement of defective parts to secure optimal functionality
- Installation of new software and precise configuration of all relevant components
- Updates to the PLC program for improved control and efficiency
- Verification and testing of all electrical connections
- Comprehensive test runs to ensure top-level performance before returning the AGVs to the customer
Measurable benefits: Economy meets environmental responsibility
Thanks to the extensive refurbishment, the AGVs are expected to remain in service for several more years, providing the customer with significant investment savings. The extended lifespan reduces the need to manufacture new units, contributing to a more sustainable production cycle. Elektroautomatik’s work reflects our strong commitment to lowering environmental impact by offering solutions that benefit our customers economically while also supporting environmental responsibility.
Sustainable refurbishment is a strategy for the future
This project showcases the tremendous potential of refurbishing and upgrading existing equipment. By giving these AGVs a new lease on life, our customer has not only realized substantial cost savings but also strengthened their sustainability efforts. Elektroautomatik demonstrates how technical expertise and environmental awareness can work hand in hand to create value across industries.