High downtime costs due to third-party spare parts. Is purchasing to blame?

11. March 2025 4 min.

Robert Seiferth, Technical Account Manager and Trainer at Robatech Germany

Increasing cost pressure is prompting decision-makers to purchase low-priced third-party spare parts instead of original parts. In the case of adhesive application systems, this decision can quickly become expensive.

Diamond nozzle from Robatech on the left and replica application nozzle on the right side

Many companies must tighten the belt: costs must be reduced. Purchasing reacts by comparing prices when procuring spare parts and tries to keep stocks low. The offers for compatible spare parts or components are tempting: convenient online ordering, short delivery times, up to two thirds cheaper. Voilà. Mission accomplished.

Calculator, calculations and red pencil

Production line managers pursue a different strategy. For them, high system availability and low reject production are on the winner's podium in the race for cost savings. But can reliable adhesive application be achieved without unplanned downtimes if third-party spare parts are used?

Spare parts: original, compatible or even counterfeit?

Third-party spare parts are components that are compatible with original products, in our case from Robatech. However, if a replica part is offered as an original Robatech part, it is considered to be a counterfeit part. In this scenario, a third-party supplier is already acting illegally.

What third-party and counterfeit spare parts have in common is the lack of adherence to key technical standards and quality controls which Robatech guarantees. Consequently, compatible spare parts become a dangerous generic product. Although they are cheaper to buy than the original, they are not sufficiently tested for safety and functionality. After all, the parts used in an application system for hot melt adhesives have to withstand temperatures of up to 200 °C and high pressures.

Caution with sensitive wear parts in hot melt application

Wear parts that fulfill a critical function in hot melt application are considered sensitive. They have a decisive influence on the productivity of the line and the quality of the adhesive application. It is therefore essential to use genuine solenoid valves, jetting elements and application nozzles, as well as filters in the melter and application head. This is the only way to guarantee that the adhesive application system operates reliably and safely.

Adhesive filters are among the most sensitive spare parts. Left genuine spare part. Original filter from Robatech on the left, third-party filter on the right.

Nevertheless, the temptation is great. For example, a replica SX-Diamond jetting element costs a third of the original price. But with a service life of 10,000 operating cycles, it is only built for one sprint, while the original Robatech part, with 250 million operating cycles, from Robatech easily completes the marathon. After every sprint, the machine comes to a standstill—driving up costs.

Hot melt application: unplanned downtime is a cost driver

Depending on the situation, an unplanned downtime can generate costs of between 1,000 and 12,000 euros per hour. Exact figures can be calculated depending on the risk of downtime. The downtime costs depend heavily on the type of product and the duration of the standstill.

Original solenoid valve on the left and original jetting element of the SX Diamond Longlife application head from Robatech on the right. Unplanned downtimes can be avoided with a genuine solenoid valve and jetting element.

Apart from the generally shorter service life of compatible spare parts, their susceptibility to malfunctions can also cause costs. A typical issue with counterfeit jetting elements: Hot melt leaks uncontrollably and flows into the machine because the application nozzle no longer closes properly. As a result, in addition to downtime costs, there are also costs for cleaning or repairs on the production line.

Is purchasing to blame?

This question is certainly provocative, but it is meant to be constructive. It is intended to encourage a holistic view of the costs of spare parts.

Stakeholders in purchasing, operations management, supply chain management and the Executive Board and Group Management should be aware of the technical risks involved in purchasing third-party spare parts. This is the only way to ensure that cost-cutting measures are not torpedoed by unforeseen high downtime costs.

Spare parts: Recommendations for reducing costs

Our experience from service assignments with customers confirms that quality and preventive measures can permanently reduce operating costs in the long term.

Robatech service technician checks the spare parts in a warehouse. It is worth having the spare parts stock checked by a service technician.

If you take the following rules to heart, you will get closer to your savings targets without risking high downtime costs.

You should not make any compromises when it comes to sensitive spare parts. Buy genuine solenoid valves, jetting elements, filters and application nozzles. This will help you avoid downtime costs, which can be far higher than the savings you are aiming for when buying third-party spare parts.
Optimize your warehousing. Keep sensitive spare parts in stock or, if possible, have a back-up system ready. Take advantage of our consulting service to find out which options are ideal for your business.
Check whether a service agreement is worthwhile for you. You will receive a discount on spare parts and training and benefit from regular, planned maintenance. This in turn increases the service life of your adhesive application system. We are also on hand should a problem occur.
Realize that trained operating and maintenance personnel is one of the best ways to reduce costs on the production line. Take advantage of our product and spare parts training courses to reduce adhesive application costs.
Have your spare parts stock checked by a service technician. If spare parts have already been in stock for some time, they should be used for maintenance or repairs. Then stock up on new spare parts. This increases your system availability, as your stock is always up to date.

Are you concerned about high downtime costs and cost-optimized spare parts management in hot melt application? Write to us! We will be happy to give you further recommendations tailored to your system.

Robert Seiferth, Technical Account Manager and Trainer at Robatech Germany

Robert Seiferth is a Technical Account Manager and Trainer at Robatech Germany. For the past 12 years, he has overseen the service hotline, supporting customers from a wide range of industries with technical problems. He passes on his know-how to customers in user training courses.

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Spare parts: original, compatible or even counterfeit?

Caution with sensitive wear parts in hot melt application

Hot melt application: unplanned downtime is a cost driver

Is purchasing to blame?

Spare parts: Recommendations for reducing costs

Robert Seiferth, Technical Account Manager and Trainer at Robatech Germany

COMMENTS

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