Extending the life of BOBST machines

Through extending equipment life, BOBST and the packaging industry win on both counts: repairing and upgrading machinery avoids environmental impacts related to the production of a new machine, and it also dramatically reduces customers’ operating costs by ensuring that the efficiency of older machines remains at its best.

As long as the consumption of resources (such as energy) by an older machine does not significantly exceed that of a new model, extending its life is worthwhile to take a smaller toll on the environment.

This is especially true for BOBST machines, which are built to last. From component selection to the assembly process and quality controls, everything in the manufacture of a BOBST machine aims to be robust and resilient. BOBST machinery is known for its reliability and longevity; compared to similar equipment available on the market, its lifespan is on average longer, lasting between 15 and even more than 30 years.

Upgrades for lasting performance are more sustainable
Equipment upgrades, retrofits, and enhancements are vital for converters to improve their productivity, remain competitive, and meet the ever-changing packaging requirements of brand owners.
Depending on the configuration, age, and condition of the equipment, an upgrade often costs less than purchasing a new machine. In addition, it extends the life of the equipment while slowing down its obsolescence. 

BOBST has deployed dedicated teams to tackle obsolescence related issues – for example, replacing electronic parts, which are one of the first parts to become obsolete, with alternative components.

But upgrading a machine to the latest standards also has the potential to reduce its environmental footprint. Retrofitting, for instance, is a great option to replace electric components with less energy-intensive alternatives.

Over 10,000 standardized upgrades are available
BOBST offers a vast range of retrofits and upgrades to solve problems of productivity, quality, or sustainability, and to extend the life of the machine:

• Annual contract to maintain critical devices (pump, chiller, coating heads) and reduce energy costs;
• Refurbishing refrigeration units with more environmentally friendly gas;
• Fluid folding to improve the quality of bending and reduce the disposable waste;
• Energy-saving motor upgrade (new IE generation);
• Improved operations for better printing on polyethylene (PE)- and polypropylene (PP)-based films using greener materials.

As of the end of 2023, 13.7% of installed BOBST machines for the folding-carton and corrugated-board industries have been upgraded to extend their lifetime or reduce their environmental impact.

Offering a second life to a 30-year-old machine
For a long time now, BOBST has offered a circularity program, through the purchase & resell of die-cutters, flexo printers and folder-gluer machines up to 20-30 years of age. This service includes a mechanical complete overhauling. For the past few years, gravure presses for flexible materials have also been completely renewed on the electrical and SW side, this made with some partners.
In 2021, BOBST acquired CM Service Srl, and it now offers an exclusive, full reconditioning service for much older corrugated machinery. The machines are taken back on site and completely renovated (including electric & software refurbishment), before being reintegrated into their customers’ production lines. 
Unique in the packaging industry, BOBST’s remanufacturing concept (which includes some “carrousel”) fosters sustainability and allows the company to extend the life of its machines while reducing its environmental impact through modernization (new electronics).
The activities of the CM Service reconditioning entity have been ramping up since BOBST took over, from 8 machines in 2022 to 13 machines in 2023. The target is to have a refurbishment capacity of around 20 large-format machines by 2025-2026. 

BOBST Oil Cleaner, an upgrade with eco-benefits
This advanced filtration technology removes impurities and contaminants from the oil used in industrial machinery. Recycling and reusing oil reduces the need for costly and environmentally damaging oil production. With clean oil, machinery becomes more efficient, which reduces the consumption of energy and carbon emissions, and has fewer impacts on the environment.

With Nexales – the Swiss publisher of digital B2B solutions – BOBST has developed a unique application for Mobile Sales to actively market its retrofit and upgrade solutions. The Group can thus offer these solutions even more efficiently to its customers, to extend their machines’ life and participate in reducing their carbon footprint.