In solid waste processing, there is a growing need to rebuild machines. Tana Second Life significantly extends the life cycle of machines, while at the same time reducing the consumption of materials needed to manufacture new machines, cutting waste and minimising emissions.
Tana’s pilot projects are currently testing how to sustainably and profitably double the life of the machine – in other words, how to give the machine a second life.
“The normal service life of a landfill compactor is 10,000 hours, after which it is either scrapped or used for spare parts. Rebuilding can give it another 10,000 hours. Even a third lifetime of similar length is possible,” says Teemu Lintula, VP, Services & Digital Solutions.
Rebuilds are different from regular maintenance or ordinary practical repairs.
“Carrying out repairs and maintenance within the normal life cycle of the machine enables it to work as efficiently as possible during its planned service life. Rebuilding, on the other hand, aims to give it a significantly extended life cycle,” Lintula explains.
The first pilot projects of Tana’s Second Life rebuild program will test how doubling the lifespan can be implemented sustainably and profitably. According to Lintula, Tana is looking into different levels, from light refurbishments to full rebuilds or upgrades of machines in use.
Tana’s starting point with its Second Life program is to offer three levels:
- Refurbishment: maintain the functional condition of the machine
- Rebuild: return the machine to its original condition
- Upgrade: improve or change the functions of the machine
Rebuilds offer both financial and environmental benefits
The timely refurbishment, rebuild or upgrade of the main components of a compactor or shredder, mainly the powertrain, offers both financial and environmental benefits. When the diesel engine and main hydraulic components hit the 10,000 operating hours mark, it’s time to take action. You’ll need to either fully refurbish or replace them to ensure continued optimal performance.
“Based on a condition assessment, it is possible to calculate in advance when a rebuild is feasible. Using data to predict maintenance is already a reality, since today’s machines are already compatible with remote diagnostics. Lintula highlights that by being aware of all the pressures and fault warnings, you can proactively assess the need for refurbishments beforehand.
“Remote monitoring produces data not only about operating hours but also about how hard the machine has been used. When a sufficient amount of data is accumulated, the estimate of the need for refurbishing and costs becomes more precise.”
Modular design simplifies rebuilds
Tana’s product development and production have always focused on the longest possible service life and easy maintenance. Making it easier to replace components and anticipate maintenance needs means less materials that need to be replaced at once. In this way, the downtime can be as short as possible.
The modular design of TANA machines streamlines rebuilds by enabling the easy replacement of entire units.
“In the future, it will even be possible to replace the diesel engine with an electric powertrain,” Lintula envisions.
Certified partners and processes ensure reliability
In practice, certified partners authorized by Tana execute rebuilds according to a standardized operating model. High-quality components and certified processes ensure that rebuilt machines retain their original performance.
The first partner, Humdinger Equipment Ltd in the USA, has already completed several rebuild projects with Tana. In North America, machines undergo up to two full-scale rebuilds during their lifetime. They even get a third life after their second life.
New network partners are starting to be certified in Europe as well. Tana has itself done rebuilds together with its network partners, and several projects are currently in progress.
Sustainable and profitable circular economy
Rebuilds must be justified not only in terms of the climate and the environment but also financially. They must be profitable for owners, as well as for Tana and its rebuild partners.
Although the proportions of recyclable components vary, rebuilding is a significantly cheaper option than purchasing a new machine. The difference to a new purchase can be in the range of 30 to 70 percent, depending on the age of the machine and the level of refurbishment.
During the rebuild, the machine’s valuable chassis structures are preserved. The owner of the machine gets guarantees for the main components that are replaced, as well as the opportunity to purchase an extended warranty.
When the need for a rebuild is systematically anticipated and the rebuild is carried out as planned, significant savings can be made in investment costs. The contractor’s productivity also increases when there are even fewer disruptions in production or they are kept short.
If the machine is not completely rebuilt, it will eventually reach the end of its service life, as before,” Lintula states.
Tana also has a clear plan for its products that provides a way to handle the final phase of their life cycle with the least possible burden on the environment.
“We have a separate recycling and refurbishment program for main components, such as diesel engines. End-of-life machines consist mostly of steel components that can be sold for metal recycling. Some components can also be recovered as spare parts,” Lintula adds.
Tana is growing in the heart of the circular economy
Tana strives for active participation in the circular economy by focusing on effectively extending the life cycle of devices. Rebuilding reduces the environmental and social costs of machine manufacturing. It is fundamentally a local operation that reduces the carbon footprint of international transport and keeps support and service close to the customer.
Although Tana’s products do not require rare earth metals, extending the life cycle of machines by rebuilding reduces waste and saves limited natural resources. For example, steel production is still energy-intensive and a major source of climate emissions.
“Tana Second Life rebuild program is a concrete step in Tana’s transition towards a circular economy. Rebuild operations in accordance with sustainable development are also an essential part of our company’s growth story,” emphasizes Kalle Saarimaa, CEO of Tana.
Aiming for a circular economy, Tana continues to develop and produce new, more energy-efficient machines, but it can also conduct profitable business by refurbishing parts and equipment. The share of maintenance and spare parts in the circular economy is increasing.
Daily inspections and maintenance play a decisive role
Teemu Lintula reminds that daily inspections and maintenance are still and will remain a decisive factor that can affect the reliability and service life of the machine in the long run.
“These are valuable machines that, as a rule, are well taken care of. We have a very extensive dealer network that is responsible for maintenance. Considering how expensive these investments are, maintenance is an effective way of guaranteeing the reliability and durability of the machines,” he emphasises.
How many TANA machines are rebuilt in the future depends ultimately on customers and the choices they make. Lintula’s educated guess is that of the more than a thousand TANA machines currently in use, perhaps every fourth or fifth could be rebuilt in the near future.
“The extensive machine base gives us a good basis for scaling up the rebuild program in the near future. To ensure quality, we are expanding our rebuild partner network carefully,” Lintula adds.