A life cycle impact assessment conducted by IPS in collaboration with Newcastle University has revealed that repairing high-value industrial assets instead of replacing them can significantly reduce environmental impact, cutting emissions by up to 40.9% for motors and 37.4% for generators.
The research assessed the environmental footprint of asset replacement versus repair across 20 years. It found that raw material acquisition, assembly, and preprocessing are among the largest contributors to environmental harm, and that asset repair plays a critical role in reducing both carbon output and resource depletion.
With industries such as mining, power generation, and transport facing increasing regulatory and financial pressures to improve sustainability, the findings present a compelling case for businesses to rethink their approach to asset management.
(This article is based on research conducted by IPS in collaboration with Newcastle University.)
Assessing the environmental cost of asset replacement
Commissioned by IPS and conducted through Newcastle University, the study evaluated the life cycle impact of three different approaches to industrial asset management:
- Full replacement of an asset at failure
- Repair after 10 years of service
- Repair at 5 years, followed by a second repair at 10 years
Using the OpenLCA program and Ecoinvent 3.8 database, the study assessed key environmental factors, including material use, energy consumption, emissions, and waste generation.
The findings underscore that extending the operational life of industrial motors and generators through strategic repair can cut greenhouse gas emissions by nearly half, while also aligning with emerging global standards on carbon reporting and resource conservation.
Key findings: The environmental and economic case for repair
Reduced carbon footprint
The study found that repair strategies could decrease Global Warming Potential (GWP) by 40.9% for motors and 37.4% for generators, primarily by preserving embodied carbon and reducing the need for new material extraction.
Embodied carbon preservation
Manufacturing a new industrial asset requires substantial embodied carbon, particularly in metals and heavy-duty components. The research found that embodied carbon accounted for approximately 50% of total GWP in all scenarios, reinforcing the environmental advantages of repair over replacement.
Energy efficiency gains
Producing and transporting new industrial assets requires significantly more energy than repairing existing equipment. Repairing assets not only extends their lifecycle but also supports broader corporate sustainability goals and regulatory compliance.
Circular economy benefits
A repair-first strategy aligns with circular economy principles, reducing industrial waste and promoting the reuse of critical components. This shift could significantly decrease the volume of discarded equipment in high-consumption sectors such as mining and power generation.
Operational and workforce sustainability
The report also emphasised the social and operational benefits of adopting a repair-focused maintenance strategy. IPS, for example, has developed a comprehensive training program to upskill engineers in advanced repair methodologies – ensuring the industry has the expertise needed to sustain long-term asset longevity.
Why asset management strategies must evolve
With rising sustainability reporting requirements, industries are under growing pressure to measure and reduce their carbon impact. While large businesses are currently mandated to disclose emissions, the study’s authors advocate for broader industry adoption of Scope 1 and Scope 2 carbon reporting, which could further drive demand for sustainable repair practices.
As businesses navigate increasing regulatory and financial scrutiny, repair-first asset management represents a viable and responsible strategy that can yield long-term financial and environmental benefits.
Looking ahead to a more sustainable industrial future
Australian Winders has long championed the extension of high-value industrial asset lifespans through best-in-class motor winding, field service, and maintenance.
The IPS and Newcastle University study reinforces what many in the industry have suspected: repair isn’t an alternative to replacement – it’s a superior strategy for asset longevity, operational efficiency, and environmental sustainability.
For more insights on industrial asset management and sustainability strategies, contact Australian Winders.
