In many workshops, the dilemma arises over whether to purchase a new robot or upgrade the one already installed. Thanks to advancements in controllers, sensors, software, and mechatronics, older components can be brought back to life effectively. The key is knowing when refurbishment makes sense and when it’s time to invest in new equipment.
Why consider modernising? A well-maintained robot can last for decades. For example, one publication notes that industrial robots, “when properly maintained, can operate for more than 100,000 hours.” Additionally, manufacturers such as KUKA offer modernisation services (“upgrade & refurbish”) to give collaborative robots or industrial robots “a second life,” extending their useful lifespan and reducing costs. Reviewing and upgrading also helps minimise downtime, makes spare parts more easily available, improves IoT/MES integration, and presents a more sustainable option.
So, when does it make sense to modernise rather than buy new? There are several technical and business criteria that can help guide the decision. If the controller or software is obsolete, no longer supported, or spare parts are hard to find or upgrades aren’t possible, modernisation might be the right choice. Kawasaki, for instance, recommends checking the age of the controller as a first step. In terms of investment, ABB says a refurbished robot can cost up to about 25% less than a new one. If the robot arm is structurally sound—its reduction gears, bearings, and axes are in good condition—then modernising by updating electronics, sensors, and software can make the most of your asset. Modernisation can also offer faster lead times and commissioning compared to acquiring a new robot. From a sustainability and ROI perspective, refurbishment involves less initial depreciation and can deliver a quicker return on investment, especially if the cell is already installed and operating well.
There are documented cases supporting this approach. An article by KUKA describes their modernisation programme: “Instead of purchasing new equipment, it is better to rely on the machines and robots you already have… A well-timed, customised upgrade or overhaul will ensure your robot systems can continue to be used over the long term.” The text explains that modernisation can lead to greater availability, less effort, improved performance, and extended system life. Another article from ABB tells of a plant with old robots that chose to modernise them because new robots were more expensive, and they valued quicker delivery and the ability to reuse the existing environment. These examples demonstrate that modernisation isn’t just a secondary option—it’s a strategically viable choice for companies seeking flexibility, speed, and ROI.
Modernising an industrial robot can be much more than a technical stop—it can become a competitive advantage. When the arm is in good working order but the electronics, software, or integration are outdated, refurbishment allows you to make the most of your existing investment and adapt to today’s automation landscape. Buying new is still necessary when the equipment is structurally worn, the remaining life cycle is low, or a major technological leap is required. But for many factories, a “second life” for a well-modernised robot can deliver nearly equivalent results at a lower cost, with shorter lead times and reduced environmental impact.
The key lies in thorough analysis, precise technical execution, and a robust service ecosystem. With these in place, a refurbished and modern robot can lead the production line as effectively as a new one.
