Remanufacturing

Woman in factory
Woman in factory

Sustainability Report

 

Nearly 50 years of providing high-quality equipment with lower owning and operating costs.

Caterpillar’s remanufacturing and rebuild operations have provided customers with quality equipment that helps deliver lower owning and operating costs.

Our engineering and manufacturing expertise, field population and dealer organization make it possible for us to offer remanufactured products and components through many of our brands and rebuild options through our dealers.

Remanufacturing and rebuild options deliver multiple sustainability benefits and help Caterpillar contribute to the circular economy. Through these activities, we recycle millions of pounds of end-of-life products annually. Because we are in the business of returning end-of-life components to like-new condition, we reduce waste and minimize the need for raw material, energy and water associated with producing new parts. Through remanufacturing, we contribute to sustainable development — extending the value of the energy and water consumed in a component’s original manufacture and keeping high-value nonrenewable resources in circulation for multiple lifecycles. The company’s enterprise strategy focused heavily on increasing services that offer superior customer value. With steady customer demand for remanufacturing products and components, we are well-positioned to help achieve this enterprise goal. Reducing waste through remanufacturing and rebuilding can provide benefits to the environment, customers and the enterprise.

127M lbs of material returned in 2021
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127M lbs of material returned in 2021
88% end-of-life eligible returns collected
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88% end-of-life eligible returns collected

2030 Goal

Remanufacturing Icon
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Remanufacturing Icon

Remanufacturing

Increase sales and revenues from remanufacturing offerings by 25% from 2018 to 2030.

Graph of sales from 2018 to 2030
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Graph of sales from 2018 to 2030

Sustainability Benefits of
Remanufacturing*

85% less energy use
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85% less energy use
61% less GHG emissions
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61% less GHG emissions
85% less material used
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85% less material used
85% less water used
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85% less water used

* Represents environmental impacts from remanufacturing process for a Cat Reman engine and components as compared to manufacturing a new, comparable engine and components. Does not include impacts elsewhere in our value chain. Based on a 2006 study done by Caterpillar on the 3412 cylinder head.

Remanufacturing Across Our Brands

Caterpillar machines and components are built to last. They are designed to withstand heavy-duty operating conditions and to be restored and used for multiple lifecycles.

Designing products and components to be used throughout multiple service lifecycles is the essence of our remanufacturing approach, which takes many different forms across our brands.

Cat Reman

The Cat Reman process returns component products at the end of their initial serviceable lives to like-new condition. Engineers use design guidelines to build key products with remanufacturing in mind, ensuring they are highly durable, even under heavy-use conditions. When a component reaches the end of its initial serviceable life, dealers can return the used component, referred to as core, to Caterpillar, where it is cleaned, inspected, salvaged and remanufactured to original factory specifications, including any relevant engineering updates. Cat Reman uses state-of-the-art salvage techniques, strict reuse guidelines, and advanced remanufacturing processes and quality controls to ensure remanufactured products provide like-new performance, coupled with a same-as-new warranty. We charge a deposit along with the purchase of each Cat Reman product, which gives customers an incentive to return their used components so that we can continue to give materials new life.

Cat Reman Engine
Cat Reman Engine

Solar Turbines

Solar Turbines remanufactures turbine components and gas compressor components. Through advanced remanufacturing processes, components are returned to like-new condition. Once components have been certified, they are placed back into service, typically through an exchange program. This allows customers to exchange major components in days rather than months of downtime. The exchange equipment is tested and certified to the same performance and emission specifications, as well as implementing the latest design improvements. Solar continues to expand remanufacturing capabilities and invest in condition-based engineering, which allows for more finite determination of remaining useful life. Condition-based engineering improves reman content and extends overhaul cycles while ensuring quality at every step. Solar continues to invest in facilities around the world to expand capabilities with the goal of reducing transportation and provide a faster customer response.

Solar Turbines Employee
Solar Turbines Employee

Progress Rail

Progress Rail extends the use of existing locomotives by providing rebuild, overhaul and repower options. These modernization programs upgrade electrical and mechanical systems and other components to extend locomotive life by 10 years or more with appropriate maintenance. Repower upgrades meet or exceed current emissions standards in certain regions while improving reliability, reducing exhaust emissions and maximizing fuel economy. We also offer reconditioning or repair services for freight cars and a wide range of components, ensuring value-added returns are available for customers, reducing annual maintenance cost. When locomotives and railcars finally reach the end of their usable lives, they can be recycled for other uses through Progress Rail’s scrap management services. We also provide rail take-up and inspection services, including grading of previously used rail, which is then recycled, repurposed for other non-rail uses or relayed into track. In 2021, Progress Rail processed about
95,000 gross tons of material.

Progress Rail Train
Progress Rail Train

Caterpillar Energy Solutions X-Change

The X-Change program is a parts replacement program for medium and large MWM branded engines and a perfect example of circular economy principles. By remanufacturing and selling X-Change parts, engines and gensets, customers benefit from quick and cost-effective overhauls and repair services on-site. This maximizes uptime of the power and heat-generating power plants for both MWM and Cat branded product lines.

The replaced parts that reached the initial serviceable lifetime are returned to Caterpillar Energy Solutions where they are cleaned, disassembled, inspected and remanufactured to like-new condition. Technology updates that reduce emissions and increase efficiency while improving reliability are included. In this way significant lifecycle extension, including greenhouse gas emission reduction, is achieved.

Caterpillar Energy Solutions
Caterpillar Energy Solutions

Caterpillar Defense

During disaster response or aid delivery, amid surge or rapid deployment, in wartime or peacetime, Caterpillar Defense responds to each operation’s needs, including offering solutions that extend the life cycle of products. Through the military Service Life Extension Program, Cat dealers give machines a complete second life cycle at a fraction of new replacement cost. We also have Caterpillar trained, qualified technicians who conduct repairs in-theater on military bases and customize replacement parts to local needs.

Cat machine on military base
Cat machine on military base

Cat Certified Rebuild

In the same spirit as Cat Reman, Cat Certified Rebuild programs increase the lifespan of equipment by providing customers with product updates at a fraction of the cost of buying a new machine, enabling us to extend the life of materials.

A complete Cat Certified Rebuild includes more than 350 tests and  inspections, automatic replacement or reconditioning of approximately 7,000 parts and a like-new machine warranty. Trained dealer service professionals perform rebuild work using genuine equipment and parts while incorporating the latest engineering updates. Caterpillar provides information, data, training and service tools to help dealers decide which parts to reuse to achieve the expected longevity of rebuilt components. Since 1985, Caterpillar and our dealers have rebuilt more than 37,000 machines, powertrains and components.

woman working on machine parts
woman working on machine parts
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