Sustainability and the waste hierarchy for machines - Part 1
“Sustainability and the Waste Hierarchy for Machines – Part 1: Machine Design Case Studies and Discussion” is a pioneering whitepaper from MTC that explores how sustainable machine design and circular economy principles can transform the environmental impact of manufacturing. This report provides a comprehensive analysis of the waste hierarchy, circularity strategies, and lifecycle assessment (LCA) as they apply to industrial machines, robotics, machine tools, and additive manufacturing equipment.
The whitepaper highlights the urgent need for UK manufacturing to integrate sustainability and circularity to meet Net Zero targets, reduce greenhouse gas emissions, and build resilience against global supply chain shocks. It introduces the 9Rs waste hierarchy—Refuse, Rethink, Reduce, Reuse, Repair, Refurbish, Remanufacture, Repurpose, Recycle, and Recover—as a framework for maximising value retention and minimising waste throughout the machine lifecycle. The report emphasises that over 80% of a machine’s environmental impact is determined at the design stage, making sustainable machine design a critical lever for change.
Through detailed case studies, the whitepaper examines best practices and challenges in the design, operation, and end-of-life (EoL) management of special purpose (SP) machines, robotics, machine tools, and rapid prototyping systems. It demonstrates how design features such as modularity, standardisation, configurability, accessibility, and digital monitoring can extend machine lifespan, enable efficient maintenance, and facilitate component reuse, refurbishment, and recycling. The report also explores the role of digital product passports (DPPs), traceability, and data-driven maintenance in supporting circularity and compliance with evolving regulations like the EU’s Ecodesign for Sustainable Products Regulation (ESPR) and the WEEE Directive.
Key findings include the outsized impact of energy-efficient design—particularly in pneumatic and motor systems—on reducing total cost of ownership (TCoO) and lifecycle emissions. The whitepaper advocates for prioritising energy efficiency, digital monitoring, and modularity in machine design, while also addressing barriers such as lack of incentives, skills shortages, and complex supply chains. It provides actionable recommendations for government, industry, and academia, including the adoption of total cost of ownership procurement, investment in skills for lifecycle extension, and the development of industry standards for sustainable machine design.
The report also discusses the importance of safety, regulatory compliance, and the need for harmonised standards to facilitate trade and innovation. It calls for collaborative action to address challenges in hazardous waste management, electronic waste, and critical minerals supply, and highlights the role of research and technology organisations (RTOs) in horizon scanning and demand planning for future regulations.
Download “Sustainability and the Waste Hierarchy for Machines – Part 1” to access expert insights, real-world case studies, and a strategic roadmap for embedding sustainability, circular economy, and waste hierarchy principles into machine design and manufacturing. Discover how your organisation can reduce environmental impact, unlock new value streams, and future-proof operations in a rapidly evolving regulatory and market landscape.