1. 重型及越野车型零配件(包括轮胎) 欧洲再制造
Shanghai , China
European Remanufacturing of Heavy Duty and Off-Road Vehicle Components (including Tyres)
重型及越野车型零配件(包括轮胎) 欧洲再制造
By Fernand J. Weiland
FJW Consulting, Cologne (Germany)
Past Chairman & now
member of the APRA board
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

2. Definition of Remanufacturing
(By European assoc. APRA, CLEPA & FIRM)
再制造的定义
“A remanufactured part fulfils a similar function as the original part . It is restored from an existing part (core), using standardized industrial processes in line with specific technical specifications. “
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

3. Remanufacturing Process for Automotive components
汽车零配件的再制造过程
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

4. European Heavy Duty Remanufacturing Introduction 欧洲重型车再制造, 概况
The European experts on Remanufacturing tend to focus mainly on the car business and less on the Heavy Duty business
That is also what I did in my last Book!
This presentation aims now at demonstrating that the Heavy Duty Vehicle Remanufacturing is as important
Editor: Fernand J. Weiland
European Automotive Remanufacturing
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

5. Light Commercial Vehicles (Are not Heavy Duty!)
轻型商务车(非重型!)
Only maximum 3.5 t total weight
Only light duty vehicle
Components very similar to cars
Hydraulic Braking no Air braking
12 Volt not 24 Volt
Transmission only 5-6 gears
Engine only in average 90 KW
Tyres only 15/16 inches Rim diam.
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

6. Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Heavy Duty Trucks,
Trailers and Buses
重型卡车, 拖车及客车
Total weight 3.6 t to 40 t
Between 5 and 8 axles
Transmissions between 9 and 16 gears
Air brakes
Electrical equipment 24 Volt
Engine from to 150 KW and 400 KW
Tyres inches Rim Diameter
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

7. Agriculture vehicles , Tractors, Combined etc
农业机械, 拖拉机, 联合收割机 等等
Special heavy duty vehicles
Total weight up to 5 t
Engines up to 250 KW – 9 liters
Hydraulic brakes
Transmission up to 25 gears
Tyres diameters up to 215 cm
Electrical supply 12 Volt and 24 Volt
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

8. Off Road, Construction,Earth Moving, Mining Vehicles etc
野外, 建筑, 地质工程, 矿山机械 等等
Heavy duty vehicles- Loaders etc
Total weight up to 30 t and more
Engines up to 250 KW – 12 liters
Hydraulic multi disc brakes
Hydrostatic Transmission
Electrical supply 24 Volt
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

9. Heavy Duty Vehicle in Use in Europe ( West & Central)
重型车在欧洲的使用 (西欧及中欧)
Number of vehicles
Trucks from 3,6 t to 40 t
Trailors (for above trucks)
Buses
Agriculture tractors
Off Road, construction, etc
Total
Light Commercial (3,5 t)
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

10. For HD Vehicles more product lines are remanufactured
针对重型车型, 再制造被更加广泛地运用
Standard components which are remanufactured for cars/light vehicles are:
Starters and alternators, power steering pumps, Fuel injection, electronic control modules, Brake calipers, transmissions, engines and turbochargers
But for Heavy Duty additional components are remanufactured such as:
Hydraulic Pumps and Cylinders
Water &Oil pumps and oil coolers
Air compressors and air actuators
Radiators & Retarders & Particle Filters
Differentials and hydraulics
Tyres and Dampers etc
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

11. HD Vehicles Components Values and Dimensions are much higher
重型车型零配件的价值更高, 适用范围更广
A few examples which clearly demonstrate how much bigger HD components are :
Brake caliper of a VW Golf : 2 ,5 kg
Brake caliper of a Commercial Truck : 40 kg
Engine of a VW Golf : 1.8 l
Engine of a Heavy Duty Truck : 12 l
Weight of a VW Golf Transmission : 40 kg
Weight of Truck Transmissions : 200 kg
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

12. Automotive (Car) Remanufacturing is very big! 汽车行业(乘用车) 再制造前途无限
But how big is Heavy Duty Remanufacturing?
The European Automotive (car) Reman business is estimated to be ca. Euro 8 billions
A very «broad brush» estimation of HD Remanufacturing can be calculated as follow:
In Europe we have 220 million cars in use compared to 20 million HD vehicles in use. Assuming a minimum of 35 % hígher wear (usage) , 25% more product lines and a component value four-five times higher,
the end result would be :
Euro …………!!!
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

13. European Remanufacturing
HD Diesel Engines
欧洲重型柴油发动机再制造
OE Manufacturers : Daimler, Volvo, FPT, Scania, Renault,
Iveco.Cummins, Caterpillar, Deutz etc
Vehicles fitted Trucks
Buses
Agriculture
Off Road
Vehicle Brand Trucks: Mercedes, Volvo, Daf,Scania,Iveco etc
Tractors/Off Road: John Deere, Caterpillar etc
Replacement Market Remanufactured ca p.a.
Repaired ?
Reman Market Share OE Reman : %
Independent Reman : %
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

14. European Remanufacturing
HD Startermotors & Alternators
欧洲重型电子器械再制造
OE Manufacturers Mitsubishi 55 %
Bosch 45 %
Prestolite, etc %
Vehicles fitted Trucks
Buses
Agriculture
Vehicle Brand Mercedes, Volvo, DAF, Scania, Iveco,
MAN, Renault , John Deere etc.
Replacement Market New machines %
Reman machines 75 %
Reman Market Shares OE Reman : %
Independent : %
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

15. European Remanufacturing
HD Truck Power Steering
欧洲重型转向系统再制造
OE Manufacturers ZF %
ZF/Thyssen 25 %
TRW 25 %
Vehicles fitted Trucks
Buses
Vehicle Brand Trucks: Mercedes, Volvo, DAF, Scania, Iveco,
Renault, Volvo & MAN
Replacement Market New units ca. 25 %.
Reman & Repair ca. 75 %
Reman Market Share OE Reman : %
Independent Reman : %
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

16. European Remanufacturing
HD Air actuated Calipers
欧洲重型空气制动卡钳再制造
OE Manufacturers Knorr Bremse 65 %
Wabco 15 %
Meritor 10 %
Haldex 10%
Vehicles fitted Trucks
Trailers
Buses
Vehicle Brand Trucks : Mercedes, Volvo,Daf,Scania,Iveco etc
Axles : BPW, SAF , ZF etc
Trailers: Krone, Schmitz Cargo etc
Replacement Market New calipers : %
Reman calipers: 25 %
Reman Market Shares OE Reman : 20 %
Independent : 80 %
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

17. Remanufacturing/Retreading Heavy Duty Tyres - The History
历史--- 重型轮胎再制造/新轮廓
Retreading Tyres is a remanufacturing process
Which started around WW II at the same time as all other vehicle components
In Europe the process is mainly applied to HD and not to car applications
In Europe OE Tyre manufacturers and ca. 200 SME companies are retreading/remanufacturing Tyres
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

18. Remanufacturing HD Tyres The Process consist of :
重型轮胎再制造过程包括以下:
Careful inspection of old Tyre casings (only sound cases/carcasses are reused)
Worn tread is buffed (removed) away
Small defects are repaired
Uncured (soft) rubber is applied on the casing
and put for vulcanizing either in a molding machine
Or pre-vulcanized treads are put on the casings for vulcanizing in a vacuum autoclave
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

19. Remanufacturing HD Tyres
The Process
重型轮胎再制造  过程
REIFENDIMENSION: 27.00R49
Gewicht: ca. 900 Kg
Photo courtesy of Rösler Tyre Innovators GmbH & Co. KG (Germany)

20. Remanufacturing HD Tyres
重型轮胎再制造
REIFENDIMENSION:35/65R33
Gewicht: ca.750Kg
Photo courtesy of Rössler Tyre Innovators GmbH (Germany)

21. Remanufacturing HD Tyres
The Products are :
重型轮胎再制造   产品
For Trucks from 7,5 tons to over 40 tons, with tyres from 17” to 24” rim diameter and weights of 30 kg to 120 kg
For Construction Equipment from 20 tons to 60 tons of overall weight and tyres from 25” to 33” rim diameter and weights of 120 kg to 750 kg
For Earth Moving & Mining equipment from 100 tons to 600 tons of overall weight and tyres from 35“ to 63“ rim diameter and weights of 700 kg to 6000 kg
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

22. Remanufacturing HD Tyres
The Benefits are :
重型轮胎再制造   优势
Retreaded Tyres cost less and reduce the total cost of operating the vehicles
New Tyres are produced in highly automated production lines, retreading/remanufacturing uses more labor and creates more jobs
The environmental balance of remanufactured Tyres is significantly better, it saves material in the amount of 60% and saves 80% of energy
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

23. Remanufacturing HD Tyres The Quality is secured by :
重型轮胎再制造      质量控制
Retreaded Tyres are as good as new Tyres
Already the quality starts with accurate inspection of old casings
The process must meet the specification UN ECR 108/109
The production facility must be certified by TUV/DEKRA etc
The final inspection ensures the required quality
The Tyres must be marked with the certified mumber and logo of the retreader
NB. Aviation Tyres are often retreaded tyres !!!
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

24. Remanufacturing HD Tyres
The Markings UN 109R
重型轮胎再制造     UN109R 标识
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

25. Remanufacturing HD Tyres
The European Market:
重型轮胎再制造    欧洲市场
The European market for replacement of HD Tyres amounts to ca. 10 million units
The market share of retreaded/remanufactured HD Tyres is ca. 3.8 million or 38 %
Car Tyres which have a low value are not attractive for retreading
The Value of Off-Road Tyres for Mining, Construction etc. is high and attractive for remanufacturing
Also Aviation Tyres are retreaded and have a high market share vs. new! Aviation tyres can be retreaded up to 5 times!!!
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

26. European Remanufacturing,
the Trends
欧洲再制造   趋势
Not as for the car business, for Heavy Duty after market sales tend to be controlled by OE players
But independent Remanufacturers are ready to fight for their part of the market
The life expectancy of components is improving which works against Remanufacturing
The components tend to become technically more complex which is in favor of the true specialists
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

27. European Remanufacturing,
the Trends
欧洲再制造   趋势
But the profit margins for HD & complex components are much better
Remanufacturing is in general a growing business (though undermined by new copied units)
The recognition as a green industry and the acceptance to service economically vehicles offers the reman industry excellent current and future business opportunities.
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)

28. European Remanufacturing,
欧洲再制造  
Xie Xie
Thank you
Organized by 再制造技术国家重点实验室 National Key Laboratory for Remanufacturing
Beijing (China)