Reman: sustainable, economical and fast

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Reman: sustainable, economical and fast

The process of remanufacturing is helping us play our part in the energy transition. By enlisting a more circular business model, we are significantly reducing our waste and emissions. But alongside the environmental impact, we are delivering added financial and time-saving benefits for our customers, too. 

The remanufacturing (or reman) process at our mtu Reman Technology Centres in Germany and the USA involves the complete dismantling, clean, repair and reassembly of used engines – even those that have already achieved up to 100,000 operating hours. They can then be granted a second life providing reliability and performance for locomotives, generators or marine vessels for thousands of hours to come.

How does the remanufacturing process work?

Paul Sixsmith

How does the remanufacturing process work?

Thousands of components, engines and systems are overhauled, repaired or remanufactured in our Reman and Overhaul Centres every year including mtu PowerPacks for railcars and Series 2000 and 4000 engines used in trains or gensets.

First, the engine is completely dismantled and thoroughly cleaned with any paint, rust or dirt removed before our engineers measure, inspect and evaluate each part to assess its condition. They then mechanically recondition and overhaul the engine and its components in the factory, working together with the original manufacturers or certified suppliers to ensure the proven quality.

Paul Sixsmith

The individual refurbished parts are reassembled and the entire engine goes through our usual testbench validation process before being primed, painted and carefully packaged for shipping.

The remanufacturing process at our German site alone saves 3,600 tons of CO2 per year, as well as raw materials. But the savings don’t end there. For our customers, a remanufactured engine is cheaper than a new engine – even with the same warranty – and can be delivered immediately, without them waiting for an overhaul on their existing engine to complete.

A more sustainable, economical and time-saving incentive

Through our reman facilities, we have been able to provide our mtu customers with a core exchange scheme, reducing downtime by replacing their existing equipment with a factory remanufactured unit and returning the original core for credit based on its technical condition.

As all replacement engines undergo the same strict processes, all remanufactured mtu engines are in the same as-new condition, regardless of the condition of the engine when it was returned to us. Customers who receive a replacement engine or components return the corresponding used parts to us, ensuring there are always enough spare parts available for the remanufacturing process to continue.

This way, each component’s lifecycle is extended for as long as is safely possible, enabling hundreds of thousands more hours of reliability and performance where our customers need it most. But what is even better – they can do it more sustainably, economically and faster than ever.

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