Going full circle: Scania proves you can use remanufactured gearboxes in production

Scania aims to cut emissions it produces in vehicle production by utilising remanufactured parts on its main assembly line in Sweden. In a world first for heavy vehicle OEMs, the iReGear research project saw a new gearbox built on the production line using remanufactured parts. The test saw 50% less new parts used and a 45% reduction in carbon emissions produced, compared to building a brand-new unit.

Fredrik Nilzen, Head of Sustainability at Scania, said: “What an achievement by the project and everyone involved. “This remanufactured gearbox is a compelling example of how the manufacturing of heavy vehicles can become more sustainable, circular and efficient, while still retaining the highest quality standards.” The ‘remanufactured’ gearbox is subjected to the same rigorous testing, to make sure they meet the quality and performance standards of new parts.

The production process showcases several environmental advantages. While replacement rates during gearbox remanufacturing can vary between 10 percent and 100 percent, depending on the wear and tear of the donor gearbox. Farazee Asif, Assistant Professor at KTH, said: “This research provides the first evidence to support the argument that it is feasible to envision future manufacturing organisations seamlessly integrating manufacturing and remanufacturing operations to develop Circular Manufacturing Systems that consume fewer resources, produce fewer emissions, and cost less without compromising on quality and performance.”

By utilising old parts to create new products, it is considered a promising strategy for OEMs to achieve their climate goals and transition towards a circular economy. In spite of its potential, remanufacturing in the European automotive sector is mainly confined to the aftermarket, which accounts for only 1.1 percent of new manufacturing according to a report by the European Remanufacturing Network (2015). Wider adoption of this process requires vehicle manufacturers to integrate the remanufactured components directly into the production lines of new vehicles, rather than selling them separately as a spare part.

It is hoped that the pioneering iReGear project will help lead the way for the industry to make this necessary shift in the efforts to create a more sustainable and cleaner transport industry. Ola Stalebo, CEO, Scandinavian Transmission Service AB, said: “STS has been remanufacturing gearboxes for more than 50 years. “It’s amazing to be able to challenge the old perception that remanufactured parts only can be used for aftermarket purposes.

“Today, we can proudly reflect on a period of successful collaboration, where we have achieved breakthroughs in sustainable technology.

This project truly shows that it might not need to stop at just one idea, but it could become a reality in the near future.”