GOOD FOR THE ENVIRONMENT – AND A BOOMING BUSINESS

It all began in 1992 in Nuremberg as an “exchange engine” business: MAN took back worn-out engines and components, or those in need of repair, reconditioned them and gave them a second life. It was an idea that fit perfectly with MAN’s sustainability strategy – the environment and the climate both benefit equally when used parts are reconditioned in a circular economy instead of simply being thrown away.

That’s why Josef Lukaschtik and his team have completely restructured and strategically redeveloped the engine and component reconditioning business in Nuremberg. It’s not a simple task. Reconditioning engines and components is a highly specialised and very individual business with high customer expectations. It all comes down to doing it properly or not at all! “For us, it’s about much more than just taking something apart, cleaning it and then putting it back together,” explains Lukaschtik.

15 TO 20 TRUCKLOADS OF USED PARTS PER WEEK

The recycling process starts when customers return old engines and components such as water pumps, flywheels or cylinder heads to MAN. They are collected at the Salzgitter factory and then sent to Lukaschtik and his team in Nuremberg – at a rate of 15 to 20 truckloads per week. Then the reconditioning process can begin. Engines, for example, are first cleaned and then checked for wear or material fatigue. Experts prepare valuable parts such as cylinder housings or crankshafts for a second life, while other parts such as seals and bearings are replaced.

At the end, you have an engine that in terms of performance and emissions is in no way inferior to a new unit – but which costs up to 65 per cent less. “We always consider the individual needs of our customers,” says Lukaschtik. “We offer them a comprehensive, worry-free package: our reconditioned components come with a two-year guarantee.” In the future, the team wants to refurbish more complex mechatronic components such as control units or exhaust gas recirculation modules too.

Top quality and first-class service

From the middle of 2018, Lukaschtik and his team began with a reworked concept and a new autonomy. Today, it is clear that their efforts have paid off – the business unit that operates under the “MAN ecoline” label has since gained fans among both internal and external customers with its top quality and first-class service.

Their entry into the circular economy has also been worthwhile for MAN, as this area is experiencing a real boom: for the 2022 financial year, Lukaschtik is set to achieve a turnover of almost € 50 million, with around 2,000 engines sold. In the meantime, 100 per cent of the engine range from Euro 5 emissions onwards is in stock as “tested basic variants”, ready for shipping in one to two days as required.

Before reconditioning: an old power take-off part in the as-delivered condition.

SCIENTIFIC MONITORING OF THE OFFER

Key to the success of MAN ecoline was the cooperation between all those experts and the collaboration with the specialist departments – including technology, documentation, controlling, order management, sales, product management and service organisation. “It was also important that we organised the supply of reconditioned parts across the whole range and were thus able to provide our customers with a one-stop-shop,” explains Lukaschtik. “Lastly, the engines and components need to be available quickly and guaranteed.”

The environment and the climate also benefit from recycling. Exactly how big these benefits are, has recently been investigated in a master’s thesis on “carbon footprint / ecological benefits of reconditioned versus newly manufactured diesel engines.” It was backed by MAN, the Fraunhofer Institute for Production Technology and Automation (IPA) and the Chair of Manufacturing and Remanufacturing Technology at the University of Bayreuth. One thing is already certain: for MAN, its customers and the environment, it has proven worthwhile to make old engines and components fit for a second life.