5 Solutions for A Sustainable Refurbishment

After more than 2 years of research and development to significantly extend the life cycle of large industrial machines through digitalisation, RECLAIM now presents its first application. 5 exploitable results that will be developed into real business cases in the coming weeks and months. All 5 have the potential to optimise your industrial process sustainably and in the long term. Technical solutions such as sensors and cameras and state-of-the-art software applications enable the user to carry out maintenance and optimisation even earlier and more efficiently. On this page, you can learn more about the 5 key developments in the RECLAIM project and receive regular updates on the latest changes.


for efficient lifetime extension of industrial equipment

Decision Support Framework for optimal lifetime extension strategies in manufacturing (e.g. refurbishing, remanufacturing), (DSF Core + Services) based on analytics of heterogeneous real-time industrial data, both raw and processed by sub-services.

Innovative aspect:

health-based recovery planning at both machine and component levels while considering

economic and environmental effects of flexible recovery decision support framework

(DSF) to assist the machinery operators and machinery manufacturers in making

efficient end-of-life decisions at different service-life periods


Machinery lifetime extension, return on investment by avoiding machinery

replacement cost, material & resource efficiency

Target and market size:

Manufacturers/producers of parts. The clinical decision support systems market

the size was valued at USD 4.48 billion (=> 4483 Million €) in 2021 and is estimated

to expand at a compound annual growth rate (CAGR) of 10.4% from 2022 to 2030

source: grand view research: clinical decision support system market.

Technological Readiness Level: 


Required Investment/ Funding:

Further training of models by data scientists on the customer side. Final integrations

among software and hardware components is required. Marketing/advertisement.


To be decided for each sub-service separately by the respective owner. For the DSF

Core the royalty price will be agreed, starting from 2000€ for non-academic license,

whereas academic licenses may be available even for free.

Bildschirm­foto 2023-02-06 um 16.35.58


for Manufacturing Machines

A tool-box combination of sensors and Intelligence that can be easily tailored to the specific case and customer, and then will engineer the collected data from machines (currently friction welding machines) to provide at least three outputs:

• Understanding the performance and use of the actual machine so customer complaints could be quickly responded and solved

• Adding value to customer providing feedback for better performance and predictive maintenance

• Diagnose the machine prior to a cost-effective refurbishment to be put again in the market for a new customer, and extend its life span

Innovative aspect:

Novel business model for manufacturing machines (Performanceoriented feedback

and service to the customer), baseline for maintenance planning, based on health

diagnosis and prediction of sensor-retrieved data from the machine directly. Opportunity

for machine leasing as part of the business model.


15-20 % reduction of breakdown time. Production efficiency (due to optimized maintenance)

and reduction of cost per part.

Target and market size:

Medium and large production companies (e.g. white goods, automotive sector (Tier1

suppliers, OEM manufacturers))

Approx. 5-10 Mio. €, including new and update of legancy machines

Technological Readiness Level: 



10.000€–15.000€ per Licence/machine


The Legacy machine booster is a combination of adaptive smart sensorial network (hardware) and real time situation monitoring. Adding sensing capabilities to highly specialiced machine equipment and tailor the monitoring to those machines in order to achieve lifetime extension.

Innovative aspect:

Combination of adaptive smart sensorial network (hardware), real time situation monitoring.

Adding sensing capabilities to highly specialiced machine equipment and

tailor the monitoring to those machines in order to achieve lifetime extension.


15-20 % reduction of breakdown time. Production efficiency (due to optimized maintenance)

and reduction of cost per part.

Target and market size:

The customers can be the various industry players which want to upgrade/enhance/

modernize their production line. In particular factories with similar machinery to the

pilots of the RECLAIM project.

It is a market that is still growing. Including the maintenance contracts it can reach tens of millions.

Technological Readiness Level: 


Required Investment/ Funding:

Marketing, stocking. The value is something negotiable, if starting really small it can

range between 50k to 100k


Price will comprise both consultancy services (analyze the initial scenario and propose

retrofitting actions) and implementation of new devices + cloud services–price will

then include an initial fee for the consultancy and a license for the cloud-based service.

REPLICA Digital twin

RECLAIM optimization and simulation cooperation in DIGITAL TWIN fault diagnostics and maintenance strategy software.

The RECLAIM optimization and simuLatIon Cooperation in digital twin (REPLICA) is a system for machinery fault diagnosis and predictive maintenance, implementing:

• The simulation environment integrating heterogeneous simulation tools;

• Algorithms for fault diagnosis, remaining useful life prediction, and maintenance.

Innovative aspect:

Combination of simulation environment and predictive maintenance


• Performing proper maintenance planning;

• Optimizing the production throughput;

• Reducing the production lines stoppages.

• Have all results in one interface–One-stop-shop —> no need for change

between softwares

• Both sensor-data and simulated data can be inputted

• Allows change of set-up in machines

Target and market size:

Any industrial sector, not sector-specific. Market size unknown

Technological Readiness Level: 


Required Investment/Funding:

Servers (infrastructure)


A business intelligence tool, working as a data sink (= storage of data) but has extended functionalities: In-built GUI. Creation of dashboards, and plotting of data. Giving the user the choice of how to visualize the data. Offers the opportunity to link it to advanced calculations/algorithms e.g. Machine Learning. 

Innovative aspect:

Automated pattern discovery (of input data) and visual representation in multiple

ways, without «telling the tool what to look for».


• Decision-making support (Significant help to decision-makers).

• Helps to understand data and underlying patterns.

• Compared to QLIK Sense (competing software): Visualisation and possible

performance differences in automated pattern detection.

Target and market size:

Any company produces vast amounts of data. Not sector-specific can be used by

any company. Can be further tailored to specific sectors if needed. Both are applicable

to large and small enterprises. (B2B mainly) Business Intelligence Tools Market: market

size unknown. To be checked.

Technological Readiness Level: 


Required Investment/ Funding:

No further investments are foreseen, other than market research/expenditures.


Similar price to a competitor. A unique advantage in terms of performance targeted.