The Many Lifecycles of a Cat Reman® Component

March 21, 2023

For 50 years, Cat Reman has put Caterpillar’s “sustainability ethos” into action. By restoring used components to like-new condition, Cat Reman creates added value for customers and reduces waste. In 2022 alone, 140 million pounds of materials were returned.¹ Follow one component through the process to see how it is transformed.

Each Cat® machine and component is a testament to product quality. We don’t just design them to perform, we build them to last. Since 1973, Cat Reman has been at the heart of our quality-focus, providing customers with options to purchase an expanding variety of remanufactured products.

Cat Reman isn’t the same as rebuilding, refurbishing, repairing, recycling or reconditioning. Instead, it’s a state-of-the-art, top-to-bottom process using the proprietary know-how of the original manufacturer. The result is a like-new component—and is created in a way that uses less new materials because we can use the existing core.

Let’s walk through a theoretical example based on real processes to better understand how Cat Reman creates value through multiple component lifecycles.

An engine block is born

Our component’s life began at Caterpillar’s engine facility in Seguin, Texas, where the team combines cutting-edge technology with good, old-fashioned teamwork. By the time an engine is fully completed, almost 100 people work together to assemble different components from the engine block to the head. Along the way, the brand new C9.3 ACERT™, an exceptionally powerful and reliable industrial diesel engine, receives a fresh coat of Caterpillar’s signature yellow paint before it finally arrives in Hot Test, where it’s powered on for the first time. During the assembly process, the team attaches a unique serial number to the engine, which service experts use to track its performance and health.

A long life building crucial community infrastructure

Like prior Cat engines, this one was destined for greatness, with engineers installing it into a D6 medium dozer. It found a home with a civil construction company near Bloomington, Indiana, whose hard-working crew clocked in six days a week. They needed a machine that was reliable, powerful and highly versatile—one that could help them handle almost any job that came their way.

The dozer delivered: It was initially deployed for a multi-year infrastructure project to improve a busy roadway that had fallen into disrepair. The crew used the machine for dozing, land clearing, finish grading and other tasks. They completed the project under budget and on time. Most importantly, the roadway was safer for cyclists, pedestrians and commuters. Later, when a storm caused damage from flooding, the crew used the D6T to help the community rebuild. Through proactive maintenance and management, and the peace of mind of a Caterpillar Limited Warranty, they kept the dozer’s engine running smoothly for several years and many projects.

The component’s first lifecycle ends

When the engine’s heavy use finally began to affect the dozer’s performance, the crew faced a pressing challenge. They needed the D6T for an important new project, yet a new engine wouldn’t be available in time. A new component would also be a costly investment at a time when the company’s budget was tight. However, after experiencing great results, they were hesitant to compromise on the quality and service that a new Cat product could provide.

The company consulted with their local Cat dealer who recommended a different approach. Through Cat Reman, their service representative explained, the company could exchange its used engine for a like-new version. The remanufactured engine also came with the latest upgrades and a same-as-new parts warranty¹. Best of all, it was available to be quickly installed, so the company placed an order right away. Meanwhile, the Cat® dealer inspected the original component—preparing it to be returned and transformed.

Through Cat Reman, a new lifecycle begins

The component’s first destination on its remanufacturing journey was Cat Reman’s Corinth, Mississippi, facility. There, the team completed further inspections before disassembling the engine down to its smallest parts. At this point, the engine lost its original identity. Now, the block was ready to be created anew.

To bring the engine block back to life, the team used a multi-part cleaning process, which removed molecular bits of debris. Once cleaned, they meticulously inspected the block for signs of cracks or imperfections before using state-of-the-art salvage procedures to reassemble it into a like-new engine. After providing several upgrades to improve reliability and performance, the team tested the engine to ensure it met the same standards as a new component.

The remanufactured C9.3 ACERT spent its second lifecycle in Oahu, Hawaii, in a 336 excavator where it served an essential role in constructing several new solar sites. Now, a component that could have ended up in a scrap yard or landfill is fulfilling an important purpose] building infrastructure and creating added value each step of the way.

The Added Value and Sustainability of Cat Reman²

Delivering thousands of like-new options

2,300+ authorized Caterpillar locations worldwide
21 global Caterpillar parts distribution centers

Sustainability Benefits of Remanufacturing

When compared to the manufacturing process of a new machine, Cat Reman provides the following sustainability benefits:

65-87% less GHG process emissions
80-90% Less new materials used
65-87% less process energy use

¹ Limitations may apply. For complete details about the applicable Caterpillar Limited Warranty, contact an authorized Cat dealer.

² Represents U.S. environmental impacts comparing "gate-to-gate" remanufacturing and manufacturing processes for engines and components. Based on 2018 external study of Cat engines, alternators and turbochargers. Does not include impacts elsewhere in our value chain

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