SciTransfer
RECLAIM · Project

Extend the Life of Your Factory Machines Instead of Replacing Them

manufacturingPilotedTRL 7
reclaim-project.eu

Imagine your factory has a big expensive machine that's getting old and breaking down. Instead of scrapping it and buying a new one — which costs a fortune — what if you could give it a "health check-up," fix what's worn out, and upgrade it with smart sensors so it runs like new? That's what RECLAIM built: a toolkit of digital diagnostics, repair strategies, and predictive monitoring that tells you exactly when and how to refurbish industrial equipment. They tested it in 5 real factories across Europe, proving you can squeeze years of extra life out of machines that would otherwise end up as scrap.

By the numbers
5
Real industrial environments where the system was demonstrated
26
Consortium partners across the project
10
Countries represented in the consortium
16
Industry partners involved in development
10
SMEs in the consortium
38
Total project deliverables produced
100%
Re-use target for industrial equipment
The business problem

What needed solving

Manufacturers across Europe face a painful choice when their large industrial equipment ages: spend millions replacing it or keep patching it until it fails catastrophically. Both options are expensive and wasteful. There's been no systematic, data-driven way to decide exactly when and how to refurbish machines to maximize their remaining useful life while keeping costs and safety risks under control.

The solution

What was built

RECLAIM produced 38 deliverables including a Decision Support system for refurbishment decisions, IoT-based health monitoring and predictive maintenance tools, digital twin simulations for fault diagnosis, augmented reality repair guidance, in-situ repair analytics, and a machinery-specific safety and risk assessment for refurbished parts. All tools were demonstrated in 5 real industrial environments.

Audience

Who needs this

Heavy machinery manufacturers with aging production lines worth millions to replaceAutomotive and aerospace parts manufacturers running legacy robotic systemsTextile and consumer goods factories with outdated but functional equipmentIndustrial maintenance service providers looking to offer predictive refurbishmentEquipment leasing companies wanting to extend asset lifecycle and residual value
Business applications

Who can put this to work

Heavy machinery and metalworking
mid-size
Target: Metal fabrication or machining companies with aging CNC machines or robotic welding lines

If you are a metalworking company dealing with aging robotic welding or CNC equipment that keeps breaking down — this project developed IoT-based health monitoring and digital twin diagnostics that tell you exactly which components to refurbish and when. Tested across 5 industrial sites, the system helps you extend machine lifetime and avoid costly full replacements.

Automotive manufacturing
enterprise
Target: Automotive parts manufacturers with legacy production lines

If you are an auto parts manufacturer struggling with legacy assembly lines that are too expensive to replace but too unreliable to trust — this project built augmented reality repair guidance and predictive maintenance tools that keep old equipment running productively. The decision support system evaluates whether to repair, refurbish, or upgrade each machine for maximum return on investment.

Textile and consumer goods manufacturing
SME
Target: Textile or packaging companies running outdated industrial equipment

If you are a textile or packaging manufacturer running equipment from a previous generation and facing pressure to modernize sustainably — this project delivered in-situ repair analytics and digital retrofitting strategies demonstrated in real factory environments. Instead of a full production line overhaul, you get targeted upgrades that extend equipment life while reducing waste.

Frequently asked

Quick answers

What would it cost to implement this refurbishment system in my factory?

The project data does not include specific pricing or licensing costs. However, the core value proposition is cost avoidance — extending machine life is significantly cheaper than full equipment replacement. Contact the consortium through SciTransfer for implementation pricing tailored to your equipment type.

Can this work at industrial scale or is it still a lab experiment?

This is well beyond the lab stage. RECLAIM was demonstrated in 5 real industrial environments with production equipment. The consortium includes 16 industry partners and 10 SMEs, meaning the tools were built and validated with actual factory conditions in mind.

Who owns the technology and can I license it?

The technology was developed by a 26-partner consortium coordinated by Harms & Wende GmbH & Co KG, a German SME. Licensing and IP arrangements would need to be discussed with the relevant consortium partners. SciTransfer can facilitate introductions to the right technology holders.

What types of industrial equipment does this cover?

RECLAIM focused on large industrial equipment including electromechanical machines and robotics systems. The 5 demonstration sites covered different equipment types, and the project specifically addressed safety and risk assessment for refurbished and re-used parts in industrial environments.

How does the system decide whether to repair, refurbish, or replace a machine?

The project built a Decision Support system that combines IoT sensor data, predictive analytics, and digital twin simulations for fault diagnosis. It evaluates machine health, predicts remaining useful life, and recommends the most cost-effective action — repair, refurbish, upgrade, or replace.

Is this compliant with EU regulations on machinery safety?

Yes — the project specifically produced a machinery-specific safety and risk assessment for refurbishment and re-use of parts in industrial environments. This deliverable addresses the regulatory requirements around putting refurbished components back into production.

How long does implementation take?

Based on available project data, the full project ran for 4 years including R&D and demonstration phases. Actual deployment of the monitoring and decision support tools at a single factory site would be significantly shorter, but specific timelines depend on equipment complexity and scope.

Consortium

Who built it

This is a strong, industry-heavy consortium with 26 partners across 10 countries. What stands out is the 62% industry ratio — 16 of 26 partners are companies, not universities. That's unusual and signals the project was built around real factory needs, not academic curiosity. The coordinator, Harms & Wende, is a German SME specializing in industrial joining technology, which means the project lead has skin in the game as a manufacturer themselves. With 10 SMEs in the mix, there's a good chance several partners are already offering related commercial services. The 5 research organizations and 3 universities provided the scientific backbone, but this project was clearly driven by industry demand.

How to reach the team

Harms & Wende GmbH & Co KG (Germany) — a manufacturing SME that coordinated the project. SciTransfer can locate the right contact person for your specific technology interest.

Order a report on this consortiumSee HARMS & WENDE GMBH & CO KG profile →
Next steps

Talk to the team behind this work.

Want to know if RECLAIM's refurbishment tools fit your equipment? SciTransfer can match your specific machinery challenge with the right consortium partner and arrange a direct introduction.

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