An industrial robot does not automatically become scrap when it leaves a production line. Depending on its condition, supportability and value, it may be repaired or upgraded, reused by another business, remanufactured, stripped for tested spare parts, or professionally recycled. The right route depends on the individual robot and applicable local requirements.
What happens to industrial robots at end of life?
“End of life” can mean a robot no longer suits a particular production job, its service support is ending, or it is no longer economical to keep running. Those situations do not necessarily mean the machine has no useful life left. Manufacturers ABB and KUKA describe services for extending use, reselling equipment, recovering components and recycling what cannot be reused.
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The usual priority is to preserve value in the most useful form: keep a working installation in service where practical; consider whole-robot reuse or refurbishment next; recover parts where the complete robot is not viable; and recycle remaining materials through an appropriate provider. This is a decision sequence, not a guarantee that every robot qualifies for each option.
What are the main options?
Repair, maintain or upgrade the installation
If the robot remains suitable for its production task, maintenance and repair may extend its service life. KUKA lists repair or exchange of defective components, maintenance, refurbishment, retrofits and used spare parts among its circular services. ABB likewise describes repair, upgrades and spare parts as ways to keep equipment in use. Availability depends on the model and its support status. ABB Circular Services; KUKA Circular Services.
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Reuse or resell the complete robot
A robot that still works may be suitable for another business or application. ABB describes a buy-back route for inactive or legacy robots; KUKA describes buy-back and third-party resale, with inspection and start-up among the services it lists. These are not universal trade-in programs: eligibility, terms and regional coverage depend on the manufacturer, model and circumstances. Ask the manufacturer or a qualified automation service provider about the particular unit.
Refurbish or remanufacture it
Remanufacturing involves inspection and reconditioning so a robot can be used again. ABB says its process follows original specifications and uses OEM-quality components, replaces worn or failed parts, conducts a 152-point inspection, and functionally tests certified remanufactured robots for at least 16 hours under nominal load. These are ABB’s descriptions of its process, not an industry-wide standard. ABB remanufacturing.
Check the exact offer and warranty rather than assuming all refurbished robots have the same inspection scope or coverage. ABB’s general circular-services page says remanufactured robots have a minimum 12-month warranty, while its dedicated remanufactured-robots page advertises 24 months. Confirm the terms for the specific unit before purchase or transfer.
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If a complete robot is unsuitable for another installation, components may still be useful. KUKA describes cleaning, testing and selling used spare parts for robots and controllers, including equipment no longer available on the market. A part’s condition and compatibility with the target robot, controller and software must be verified; a used component is not automatically interchangeable simply because it appears to fit.
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Recycle what cannot be reused
When repair, whole-unit reuse and parts recovery are not viable, the remaining equipment can be dismantled so material fractions can be directed to recycling or final disposal. ABB says the portion of a robot that is not reused goes to certified recycling partners. ITU-T Recommendation L.1037, issued in September 2025, addresses environmentally sound collection, transportation, storage, dismantling, valorization and final disposal of waste electrical and electronic equipment (WEEE). It is guidance for environmentally sound handling, not a determination of the legal requirements that apply at a particular site. ITU-T Recommendation L.1037.
How do you choose the right route?
There is no universal break-even threshold or cost formula in the cited manufacturer and ITU materials. Compare the robot’s technical condition and practical costs with its reuse and recovery possibilities:
- Condition: assess mechanical and electrical state, known faults and the work needed to return the robot to reliable operation.
- Support: establish whether parts, service and technical support remain available for the robot and controller.
- Compatibility: check whether the controller, software, tooling, safety system and production process can be supported or adapted for the next use.
- Costs and value: compare inspection, repair and commissioning costs with potential resale value or the value of recoverable parts.
- Removal and logistics: account for disconnection, handling and transport requirements for the equipment.
- Local obligations: check applicable waste, environmental and producer-responsibility requirements, and verify the receiving provider’s qualifications.
For a specific asset, ask the manufacturer or a qualified automation service provider to assess the model, condition, supportability and likely route. A general service description cannot establish that an individual unit is eligible for buy-back, remanufacturing or resale.
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ABB publishes several figures about its own remanufacturing and take-back activities. The company’s cited pages do not state a publication year, and the figures are ABB claims rather than independently verified industry-wide results:
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- ABB says it has remanufactured more than 12,000 robots globally.
- ABB says 60–80% of a robot can be reused, with the rest sent to certified recycling partners.
- ABB says refurbishment produces 75% less CO2 than producing a new robot; the page does not state the assessment boundary or methodology.
- ABB says it takes back around 250 robots per year.
- For its remanufacturing process, ABB describes a 152-point inspection and at least 16 hours of functional testing under nominal load.
These numbers describe ABB’s published claims and process; they should not be applied to other manufacturers or treated as a guaranteed outcome for an individual robot. ABB Circular Services; ABB remanufacturing.
What happens to robot parts that cannot be reused?
Parts that are not suitable for repair or resale become part of the remaining material stream. Their handling depends on the equipment and local rules: a qualified provider can dismantle the robot, separate materials for appropriate recovery, and direct unrecoverable fractions to final disposal. Before handing equipment over, confirm what the provider accepts, how it documents the work and whether its qualifications meet local requirements. ITU-T Recommendation L.1037 covers environmentally sound WEEE handling processes, but local law determines the obligations for a specific owner or site.
Can I sell an old industrial robot back to the manufacturer?
Possibly. ABB describes buying back inactive or legacy robots, and KUKA describes buy-back as part of its circular services. Neither description establishes that every make, model, condition or location is eligible. Contact the relevant manufacturer or its regional service channel with the robot’s model, serial details, controller information, condition and location to ask about current terms. ABB Circular Services; KUKA Circular Services.
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