industrial automation Archives

Refurbished vs New Industrial Robots: ROI Comparison

When companies plan industrial automation projects, one key question consistently drives the decision-making process: how quickly will the investment pay for itself? Return on investment (ROI) is often more critical than raw performance or technology novelty. While new industrial robots offer the most recent hardware and software innovations, refurbished industrial robots—professionally restored and tested to operate like new—have become a strategic alternative for manufacturers seeking faster payback and controlled capital expenditure.
This article provides a technical and economic comparison between refurbished and new industrial robots, focusing on ROI-relevant variables such as initial investment, total cost of ownership, deployment speed, depreciation, reliability, and application suitability. The goal is not to promote one option universally, but to support data-driven decisions aligned with business objectives.

Why ROI Matters More Than Ever in Industrial Automation
Industrial automation is no longer only about increasing throughput. In today’s manufacturing environment, ROI must account for:

Capital expenditure constraints
Workforce availability and costs
Production flexibility requirements
Risk exposure and operational continuity
A robot that is technically superior but underutilized may generate a slower ROI than a simpler, lower-cost system perfectly matched to the application. This is where the refurbished versus new robot comparison becomes especially relevant.

Initial Investment and Total Cost of Ownership (TCO)
New Industrial Robots
New industrial robots generally involve a higher upfront investment. This cost reflects:

Latest-generation hardware and controllers
Full manufacturer warranty
Long-term software roadmap
Compatibility with the newest peripherals
However, these advantages do not automatically translate into higher efficiency. If an application does not require advanced features such as AI-driven path planning or high-resolution vision integration, part of the investment may remain unused.

Refurbished Industrial Robots
Refurbished robots are previously used units that have been disassembled, inspected, restored, and tested to meet defined operational standards. When properly refurbished, these robots deliver reliable performance at up to 40–60% lower acquisition cost compared to comparable new models.
This price difference allows companies with limited automation budgets to:

Accelerate automation roadmaps
Deploy multiple robots instead of one
Reduce financial exposure per cell
From a TCO perspective, a lower initial investment often has a direct and positive impact on ROI calculations.

Deployment Time and Speed to Value
Time-to-Production as an ROI Driver
The faster a robot generates productive output, the faster it contributes to ROI. Deployment timelines depend on availability, configuration, and integration complexity.

New Robots: Longer Lead Times
New robots frequently involve:

Manufacturing lead times
Custom configuration and testing
Shipping delays
Extended commissioning phases
In some cases, these factors can delay production start by several months, postponing ROI realization.

Refurbished Robots: Faster Integration
Refurbished robots are often available from stock, allowing integrators and manufacturers to:

Begin system integration sooner
Reduce commissioning time
Launch production earlier
For standard applications, this faster deployment can significantly shorten the time required to recover the initial investment.

ROI Explained: Key Financial Drivers
ROI compares net operational benefits against total investment. In robot selection, three dimensions strongly influence the result.
Cost Versus Benefit Balance
A refurbished robot’s lower purchase price can yield faster ROI, even if its specifications are slightly below those of the latest model. In many real-world scenarios, productivity and cost savings compensate for the absence of cutting-edge features.
Depreciation Profiles
New robots tend to depreciate rapidly, particularly when newer generations are released. Refurbished robots already reflect market-adjusted value, resulting in slower and more predictable depreciation.
Payback Period
Thanks to reduced capital cost and faster deployment, refurbished robots often achieve payback in shorter timeframes—especially in applications that do not require advanced sensing or AI capabilities.

Reliability and Productivity Considerations
Are Refurbished Robots Reliable?
A common concern is whether refurbished robots can match the reliability of new units. When refurbishment follows a structured process—including precision testing, component replacement, and lifecycle validation—performance can be comparable to new equipment.
New Robots: When Technology Matters
For applications involving:

Advanced machine vision
AI-based decision logic
High-speed collaborative operation
new robots may offer a technical advantage. However, for standard tasks such as material handling, palletizing, welding, assembly, or machine tending, refurbished robots are highly competitive.

Application Suitability: Choosing the Right Tool
The best robot is not always the newest—it is the one that best fits the task.
Typical Applications for Refurbished Robots

Pick and place
Palletizing and depalletizing
Arc and spot welding
CNC machine tending
Basic assembly operations
Applications Favoring New Robots

Vision-intensive inspection
Human-robot collaboration with advanced safety
Rapid multi-product changeovers with AI optimization

Strategic Perspective: Flexibility and Risk Management
Refurbished robots offer an opportunity to spread automation risk. Instead of committing large capital to a single system, companies can test automation concepts, scale gradually, and preserve financial flexibility.
This approach is particularly relevant for:

Small and medium-sized manufacturers
Companies automating for the first time
Plants with uncertain demand forecasts

The Role of the Integrator and Supplier
The success of refurbished or new robots depends heavily on how the solution is engineered and supported.
URC focuses on matching robot selection to process requirements, lifecycle expectations, and financial targets, ensuring that both refurbished and new robots deliver measurable results rather than theoretical performance.

Frequently Asked Questions (FAQ)
Do refurbished robots perform like new ones?
Yes, when restored and tested by qualified specialists, refurbished robots can deliver comparable operational performance.
Are refurbished robots cheaper to maintain?
Maintenance depends more on usage and duty cycle than on whether a robot is new or refurbished. However, lower purchase cost often results in a reduced total cost of ownership.
What factors most influence ROI?
Initial investment, deployment time, productivity gains, operational life, and maintenance costs.

ROI Evaluation Checklist

Compare initial cost between new and refurbished robots
Analyze deployment and commissioning time
Match robot capabilities to process requirements
Estimate payback period in months or years
Include long-term maintenance and energy costs
Verify spare parts availability and technical support

External Sources and References

International Federation of Robotics (IFR) – World Robotics Reports
https://ifr.org

ISO 10218 – Safety of Industrial Robots
https://www.iso.org

McKinsey & Company – Automation and Capital Productivity
https://www.mckinsey.com

Internal Links (Suggested)

Refurbished Industrial Robots
Industrial Robot Integration Services
ROI Analysis for Automation Projects

Call to Action (CTA)
URC supports manufacturers in evaluating and deploying both refurbished and new industrial robots based on real ROI, process requirements, and long-term sustainability. From feasibility analysis to system integration, URC helps organizations make automation investments that deliver measurable value.
If your company is considering automation or evaluating whether refurbished or new robots are the best choice, URC can help you identify the most effective solution for your operational and financial objectives.

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When Does It Make Sense to Automate Only Part of the Process?

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For years, automation was framed as an absolute goal:
either everything was automated, or nothing was.
In real industrial environments, that logic rarely works. Processes are more complex—and often more efficient—when not forced into an all‑or‑nothing decision.
Partial automation is not a compromise. It is a strategic choice.
One that requires understanding where robots create stability and where humans add irreplaceable value.
The real question isn’t “Can we automate everything?” but rather:
“Should we?”

Why Partial Automation Makes Sense
Some tasks benefit massively from robotic precision—repetitive movements, heavy lifting, defined trajectories, sustained physical strain.
Other tasks rely on human capabilities—variability handling, contextual judgment, rapid adaptation.
Forcing robots to replace both often results in:

Over‑engineered systems
Rigid processes
High reprogramming costs
Reduced productivity over time

The most successful automation projects strike a balance:
robotic repeatability + human flexibility.

Problems Caused by Over‑Automation

The system becomes heavy and difficult to maintain
Every new variation requires reprogramming
Exceptions become disruptions rather than manageable events
Operators feel disconnected from the system
Productivity may decrease instead of improving

Automation should adapt to the process—not force the process to adapt to the automation.

When Partial Automation Is Technically the Best Option
Partial automation is ideal when a process contains both:
1. High‑repeatability segments

Repetitive motions
Physically demanding operations
Precise and stable trajectories
Tasks requiring constant accuracy

2. High‑variability segments

Situations requiring human decision‑making
Context‑dependent adjustments
Handling of unpredictable elements
Quality checks requiring interpretation

In these hybrid systems, interface design is crucial—both physical and digital. Operators and robots must transition seamlessly between roles without friction or risk.

The Human Factor: The Most Overlooked Part of Automation
Partial automation acknowledges that human value does not disappear—it shifts.
Operators evolve from executors to:

Supervisors
Adjusters
Process interpreters

When this transition isn’t supported, systems fail for human—not technical—reasons.
A robot may work perfectly, but the team doesn’t trust it, doesn’t understand it, or feels displaced by it.
Projects that succeed:

Do not aim to replace people
Redistribute intelligence between humans and machines
Preserve a visible, meaningful human role

This clarity increases adoption and reduces resistance.

The Paradox: More Flexibility Through Less Automation
The most flexible systems are often those that didn’t attempt full automation.
Leaving deliberate room for human intervention gives:

Faster adaptation to product or process changes
Reduced need to redesign the entire cell
More resilience and robustness over time

Partial automation is not “halfway.”
It is strategic efficiency—not extremism.
Key Principles
Benefits of Partial Automation

Balances robot stability with human adaptability
Reduces system rigidity
Lowers long‑term programming costs
Helps handle variability and exceptions smoothly
Increases team acceptance and engagement

Risks of Full Automation

Over‑complexity
Higher maintenance and reprogramming needs
Reduced flexibility
Lower resilience to real‑world variability
Human–machine mistrust

Ideal Conditions for Partial Automation

Mixed repeatability and variability
Processes requiring both precision and judgment
Situations where human adaptation adds value
Systems with frequent product changes

Checklist: Should You Automate Everything or Only Part of It?
Evaluate repeatability

Are parts of the process strictly repetitive?
Do these steps require consistent precision?
Do they involve physical strain or risk?

Evaluate variability

Are there steps requiring human judgment?
Do operators frequently adjust parameters or conditions?
Are there elements that cannot be predicted?

Evaluate system flexibility

Will the process evolve over time?
Would full automation make updates slow or costly?
Do operators need to intervene regularly?

Evaluate human–machine collaboration

Does the team understand the system?
Will people still have a meaningful role?
Is there a risk of resistance or loss of trust?

If many boxes are checked, partial automation is likely the best strategy.

FAQ — Partial Automation in Industrial Processes
Is partial automation a sign of project failure?
No. It is a strategic decision used in the most efficient production environments.
Why not automate everything if the technology exists?
Because many tasks require adaptability and judgment that robots cannot replicate efficiently.
Does partial automation reduce ROI?
Often the opposite: it reduces costs, increases flexibility, and shortens update times.
Can partial automation improve worker satisfaction?
Yes. Workers shift to higher‑value tasks, reducing fatigue and increasing engagement.
Does partial automation make the system more complex?
No—full automation is usually more complex. Hybrid systems offer better balance and maintainability.

Final Thought
Partial automation is not about doing less. It’s about doing what works best.
The most efficient systems are those that know exactly where to stop automating.

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HOW LONG DOES IT REALLY TAKE TO COMMISSION A ROBOTIC CELL?

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When discussing automation, one question inevitably arises: “How long will the line be down?” This is not a matter of technical curiosity—it’s a reflection of real pressure. Production is at stake, customers are waiting, shifts are scheduled, and people are watching the calendar. Commissioning is not just another project phase; it is a critical moment

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High-Impact Applications That Work Perfectly with Refurbished Robots

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The Global Trend Toward Accessible Automation The industry is undergoing an interesting shift: many companies are automating processes using refurbished industrial robots because they deliver the same level of functionality for a wide range of applications—especially in cases where cutting-edge technology is not essential. This trend is evident in sectors such as automotive, metalworking, plastics,

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REAL CASES IN LATIN AMERICA: HOW SMES CUT COSTS WITH REFURBISHED ROBOTS

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For years, industrial automation seemed to be the exclusive realm of large conglomerates. However, the market for refurbished robots is changing that, especially in Latin America, where manufacturing SMEs are striving for efficiency without making multi-million investments. Traditionally, tasks such as mould manufacturing, welding structures, or handling parts on production lines require high precision, but

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FROM THE FACTORY TO THE SMART ECOSYSTEM: THE RISE OF ROBOTIC SWARMS

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Swarm robotics, inspired by the behavior of social insects, is no longer just a laboratory concept—it’s becoming a practical solution in industries such as logistics, construction, and advanced manufacturing. This approach enables multiple robots to work together in a decentralized manner, tackling tasks that once required complex centralized systems.

The Essence of Swarm Robotics

Unlike traditional automation systems, where each robot is controlled by a central unit, swarm robotics relies on distributed autonomy. Each robot follows simple rules, but collectively they generate intelligent, adaptive behavior that responds in real time to changing conditions. This makes swarm robotics ideal for dynamic environments like warehouses or assembly lines, where constant variation is the norm.

Breakthroughs in Research

One of the most notable recent developments is RoboBallet, a project led by University College London (UCL) in collaboration with Google DeepMind. It coordinates up to eight robotic arms to perform 40 tasks within seconds. Using AI algorithms, the system prevents collisions and optimizes group movements—marking a milestone in multi-robot planning.

Other programs, such as Centibots and Symbrion, have long demonstrated that simple robots can self-organize to explore spaces, transport objects, or even assemble into cooperative structures. Backed by research institutions in the U.S. and Europe, these initiatives laid the groundwork for today’s industrial swarm robotics.

Emerging Industrial Applications

The automotive industry is among the first to embrace this paradigm. Companies like Arrival have documented assembly processes where groups of robots simultaneously build electric vehicles—eliminating the need for a static production line. This approach offers greater flexibility, lower costs, and adaptability for small or customized production runs.

In logistics, large warehouses are experimenting with fleets of mobile robots that self-organize to move goods more efficiently than traditional systems. The key lies in their independence: each robot makes local decisions that, together, result in a coordinated and seamless operation.

Swarm robotics is reshaping the landscape of industrial automation. What began as an experimental concept inspired by insect behavior has evolved into a practical model that enhances resilience, flexibility, and efficiency in factories and logistics centers.

Advances in AI, inter-robot communication, and distributed planning are driving adoption in strategic sectors like automotive and logistics. In the coming years, we’ll witness mass production shift toward dynamic networks of collaborative robots—capable of operating as a self-sufficient, adaptive swarm.

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YASKAWA AND MULTIVAC: PACKAGING INNOVATION WITH RX 4.0 THERMOFORMER AND SIX-AXIS ROBOT

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In the fast-moving world of industrial automation, the collaboration between Yaskawa and MULTIVAC marks a significant milestone. The integration of Yaskawa’s six-axis MOTOMAN HD7 robot into MULTIVAC’s RX 4.0 thermoforming machine sets new standards in the medical and pharmaceutical industries, fully aligning with stringent Good Manufacturing Practice (GMP) regulations.

A New Era in Packaging Innovation

The RX 4.0 thermoformer by MULTIVAC was designed to meet rising demands for precision and consistency in packaging sensitive products across healthcare sectors. More than just reducing production times, the system enhances operational efficiency and adaptability. A standout feature is the first-ever incorporation of a six-axis Yaskawa robot at the end of the production line, bringing unprecedented flexibility to the packaging process.

MOTOMAN HD7: Precision Meets Versatility

Chosen after a rigorous market analysis, the MOTOMAN HD7 stands out for its cleanroom compatibility and full GMP compliance. Developed in collaboration with the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA), this robot is suitable for environments ranging from ISO Class 5 to GMP Class A — the highest hygiene standard.

Its six-axis structure allows both single and multi-point loading and unloading operations. In demo setups, it’s been equipped with a five-point vacuum head for handling packages, which can be placed onto moving conveyor belts or at fixed, designated positions. The HD7’s range of motion enables it to access various positions without constraint, offering remarkable format flexibility.

Seamless Integration and Smart Control

The robot’s integration into the RX 4.0 platform is made possible through Yaskawa’s MotoLogix software interface, which embeds robotic kinematics directly into MULTIVAC’s control system and programming environment. This ensures centralized line operation from a single platform, boosting efficiency and streamlining system complexity.

The partnership between Yaskawa and MULTIVAC in deploying the MOTOMAN HD7 represents a significant leap forward in packaging automation for the medical and pharmaceutical industries. Not only does it enhance process precision and flexibility, but it also sets a new benchmark in GMP compliance—ensuring consistently high product quality and safety.

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THE DIGITAL REVOLUTION IN FEED MANUFACTURING: THE PROGANDO SUCCESS STORY WITH ARBENTIA AND MICROSOFT

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In the era of Industry 4.0—where connectivity and automation are reshaping every industry—digitalizing processes has become essential for staying competitive. A clear example of this transformation is Progando, a leading Galician company in animal nutrition, which has achieved a major milestone by integrating its feed manufacturing and sales operations through a strategic collaboration with ARBENTIA and Microsoft. This project not only streamlines management but also lays the foundation for a smarter, more responsive value chain.

Rooted in the Provincial Agricultural Cooperative of A Coruña (Leyma) and deeply committed to rural development, Progando faced the challenge of unifying and monitoring its complex feed production and distribution processes, along with managing its ProSardín retail stores. The solution came with Microsoft Dynamics 365 Business Central, a cloud-based ERP system that enabled Progando to consolidate all its operations into a single database.

Led by ARBENTIA, the implementation resulted in full integration of workflows—from purchasing and finance to logistics and production. This advanced digitalization allows real-time monitoring of both the factory and the stores, ensuring tight inventory control, batch traceability, and compliance with food safety and quality regulations. Integration with tools like Microsoft Power BI has further empowered Progando with robust analytics capabilities, enabling faster, data-driven decision-making.

“We aimed to integrate all our workflows and make better decisions using tools like Microsoft Power BI,” explains Adrián Veras from Progando, highlighting how technology has elevated the value of their work and allowed the team to focus on higher-value tasks.

Progando is a family-run Galician company and a benchmark in the animal nutrition and agricultural distribution sector. Operating within the Leyma cooperative, its mission is to support farmers and develop cutting-edge technologies for agricultural production, promoting efficiency and sustainability in rural areas. In a year of strong growth, the company reported €69.5 million in revenue and reached a record production of 120,000 tons.

ARBENTIA, a digital transformation expert, supports businesses in their technological evolution. Specializing in the development and implementation of intelligent solutions based on Microsoft Dynamics 365, ARBENTIA focuses on improving efficiency, traceability, and profitability across the entire value chain—from production to distribution. It positions itself as a key strategic partner in business modernization, offering specialized software for feed distribution and promoting operational excellence.

Microsoft, the global tech giant, is a leading provider of software, services, and solutions that transform how businesses operate. In this project, its Dynamics 365 Business Central and Power BI platforms form the digital backbone, delivering the cloud infrastructure needed for integrated, flexible, and scalable management. Microsoft’s technology is essential for boosting operational efficiency and enabling powerful data analysis, bringing the vision of Industry 4.0 to life for companies of all sizes and sectors.

This success story underscores how the right combination of strategic vision, advanced technology, and expert implementation can lead to full digital transformation of industrial processes—marking a turning point in the efficiency and competitiveness of the agri-food sector.

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FROM JOB CREATION TO PRODUCTIVITY IN THE AGE OF AUTOMATION

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In a world where efficiency and competitiveness are essential, industrial automation emerges as a key tool for transforming productivity. However, in countries like the United Kingdom, the adoption of robotic technologies still faces significant challenges.

The Reality of Automation in the United Kingdom
According to recent data from the International Federation of Robotics, the UK ranks 23rd in robot density worldwide, with only 119 robots per 10,000 workers, compared to a global average of 162. Excluding the automotive sector, this figure drops to 69 robots per 10,000 employees.
This low adoption of automation is reflected in the country’s productivity. In the fourth quarter of 2024, British productivity was 0.8% lower compared to the previous year and 19% lower than that of the United States.

Beyond Job Creation
One of the obstacles to adopting automation is the focus on job creation. While generating jobs is important, it is crucial to recognize that automation does not aim to replace workers but to complement their skills. Robots can handle repetitive and dangerous tasks, allowing employees to focus on work that requires creativity and critical thinking.
Additionally, automation can help address labor shortages and skill gaps in the manufacturing industry. By automating certain functions, companies can maintain production without relying solely on a workforce that is often hard to find.

Attracting New Generations
The manufacturing industry faces the challenge of attracting young talent. The perception of monotonous and physically demanding jobs deters many. However, integrating advanced technologies like robotics and artificial intelligence can change this image. Offering a modern and technologically advanced work environment can be key to capturing the interest of new generations.

Looking Beyond Initial Costs
One reason many companies, especially SMEs, hesitate to adopt automated solutions is the perception of high initial costs. But focusing solely on the purchase price of a robot or automated system is a limited view. This is where the concept of Total Cost of Ownership (TCO) comes in.
TCO includes not only the acquisition price but also installation, training, operation, maintenance, energy consumption, and eventual replacement costs. In other words, all the expenses the company will incur over the robot’s useful life.
Adopting this approach allows companies to see the bigger picture: a seemingly more expensive solution may be much more cost-effective in the medium and long term if it reduces downtime, improves energy efficiency, or decreases reliance on external maintenance.
In a context of inflation, skilled labor shortages, and pressure to maintain competitive margins, thinking in terms of TCO is strategic thinking.
The Way Forward
To boost productivity and ensure competitiveness, it is essential to rethink perceptions of automation. Instead of viewing it as a threat to employment, we should highlight its ability to revolutionize the industry, optimize the work environment, and stimulate innovation.
Investing in automation not only benefits large companies but also offers small and medium-sized enterprises the opportunity to expand and adapt to global market demands. By adopting these technologies, the UK and other countries can ensure a prosperous and sustainable future for their manufacturing sector.
It is time to shift the focus from job creation to productivity improvement through automation, recognizing that collaboration between humans and machines is the path to a more efficient and resilient industry.

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MOBILE ROBOTS OR HUMAN WORKERS? A DICHOTOMY THAT NO LONGER MAKES SENSE

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For years, the discussion about whether machines will replace people has marked the debate in industrial automation. However, in the current context of accelerated technological transformation, posing this dilemma as a direct competition between mobile robots and human personnel is not only simplistic but counterproductive. In reality, intelligent collaboration between both actors is proving to be the true driver of industrial progress.
More than competition: a strategic alliance
The “robots vs. humans” approach is an increasingly obsolete proposition. Leading automation companies have already understood that the future of productivity and efficiency does not depend on replacing people with machines, but on leveraging the best of both worlds. While mobile robots (AMR, for its acronym in English) provide precision, speed, and continuous availability, human operators offer judgment, adaptability, and problem-solving ability in complex contexts.
Tangible advantages of integrating mobile robots
The acquisition of autonomous mobile robots can generate significant benefits from day one, especially in logistics, industrial, and manufacturing environments. Some of the most notable advantages are:
Reduction of downtime and unnecessary movements: AMRs optimize routes and perform internal deliveries with millimetric efficiency, allowing human operators to focus on higher-value tasks.
Greater job security: Mobile robots can take on repetitive or dangerous tasks, minimizing risks for personnel.
Operational scalability: Faced with increases in demand, scaling with mobile robots is faster and more flexible than hiring and training new employees in the short term.
Real-time data and traceability: Modern AMRs generate key information for continuous improvement, such as circulation heat maps, logistics flows, and delivery times.
In which tasks do mobile robots excel?
Mobile robots are especially effective in tasks where repetitiveness, precision, and autonomy are key. Some examples of outstanding applications include:
Internal logistics: Transport of materials, parts, and tools between workstations.
Hospital environments: Delivery of medicines, samples, and food autonomously and safely.
Distribution centers and e-commerce: Optimization of picking and product replenishment.
Industrial manufacturing: Supply of production lines and movement of semi-finished products.
Robots and humans: a powerful synergy
Far from replacing staff, mobile robots are designed to collaborate with them. Collaborative robotics — both fixed and mobile — prioritizes safety and smooth integration with the human environment. Modern AMRs have advanced sensors, SLAM mapping, and dynamic navigation that allow them to move in shared spaces without interfering with human activities.
Moreover, delegating the most routine or physical tasks to robots frees human teams to focus on functions that require technical judgment, analysis, or interpersonal contact.
Do not give up human value: train and empower your team
Investing in mobile robotics should not imply a reduction in human talent, but an opportunity for its revaluation. Training staff in the use, supervision, and maintenance of robots can open new professional doors within the organization. Operators cease to be “labor” to become technical supervisors, system integrators, or responsible for operational data analysis.
By training your team in this technological transition, you not only improve their employability but also reinforce their commitment and sense of belonging in an evolving environment.
Integration, not substitution
The true qualitative leap in the industry does not come from choosing between people or robots, but from learning to combine them intelligently. Mobile robots are not a threat but a strategic tool to make companies more competitive, operations safer, and people more valuable.
Incorporating technology without losing sight of the human factor is the key to sustainable, efficient, and human automation.

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