Sustainability is driving meaningful progress in the industrial equipment industry, reshaping how equipment is designed, built, operated and maintained. The industry is evolving to align with circular economy principles, where equipment is increasingly designed for durability and resource efficiency while making repair, upgrades and repurposing more straightforward.

Manufacturers use virtual twins to refine product development, reducing reliance on physical prototypes and virtually optimizing production and assembly. Meanwhile, Industrial Internet of Things (IIoT) sensors, AI-powered analytics and self-monitoring systems optimize equipment performance in the field by anticipating maintenance needs and limiting downtime through continuous real-time monitoring. Modular designs also allow components to be swapped or upgraded instead of discarded, where machines are systematically disassembled at the end of their lifecycle so valuable components can be reintroduced into the supply chain. The shift towards circularity is redefining sustainability and performance standards across the industry.

From Linear to Circular: The Sustainable Revolution in Industrial Equipment

Sustainable manufacturing: Cutting waste, energy consumption and emissions in production is now essential for long-term success. Factories are adopting smarter production methods such as replacing traditional die cutting with laser cutting to use materials more efficiently. Remanufacturing – restoring used equipment to like-new condition – alone can lower costs up to 20% to 60%. Manufacturers are also refining sourcing strategies, improving plant efficiency and using virtual simulations to streamline production before implementation. Furthermore, virtual twins help limit material waste while shifting to renewable energy, reducing reliance on fossil fuels. Data-driven insights are also used to improve efficiency, lower costs and strengthen sustainability efforts.

Circular supply chains: Industry executives report that circular supply chains – where materials are reused, remanufactured or recycled – cut material use by 28% on average, lowering costs and reducing reliance on scarce materials. At the same time, circular practices eliminate 39% of greenhouse gas emissions, making a tangible difference in sustainability efforts while improving overall efficiency. Moreover, greater transparency in sourcing allows manufacturers to track sustainability from extraction through to end-of-life, ensuring compliance with evolving regulations and reinforcing their commitment to sustainable practices.

A Path to Circular Innovation for Industrial Equipment

Today, almost half of large industrial equipment companies have made circularity commitments, yet many still treat it as a regulatory requirement rather than a business opportunity. Forward-thinking manufacturers recognize that circularity isn’t just about compliance; it’s a path to new revenue streams, supply chain resilience, and stronger customer relationships.

Widespread research suggests that manufacturers who embed circularity into their business models gain a competitive edge. They secure access to limited materials, lower supply chain risks, and generate new, recurring revenue opportunities by selling services alongside products. 

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Dassault Systèmes’ integrated solutions bring new ways for companies to explore the potential of circular innovation, allowing them to rethink how they design, produce and manage their equipment across the entire lifecycle – even into a second life.

With the 3DEXPERIENCE® platform, industrial equipment companies can analyze the environmental and ethical impact of their products early in the design and engineering stages, considering recyclability from the start.

Manufacturers that rely on a centralized platform will seamlessly connect their operations and transform their plants into sustainable factories. Data-driven insights and organization-wide visibility help them to optimize their manufacturing plans, factory spaces and layouts, and find new ways to manage waste.

The 3DEXPERIENCE® platform provides companies with fast and efficient access to up-to-date and trustworthy data from multiple sources, including connected equipment in the field. Dassault Systèmes’ advanced analytics capabilities interpret evolving standards, complex product structures and vast data models, revealing actionable insights in user-customized dashboards.

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