The circular economy in practice: Audi Genuine exchange parts

Audi is working to use resources more efficiently throughout the value chain and to embed the principle of the circular economy more firmly into the development, production and use of its vehicles . At the same time, Audi vehicles are subject to defined quality requirements. These take into account, among other things, a long service life and the ability to withstand sustained use. Should a part nonetheless need to be exchanged, Audi offers three different exchange options for selected parts:

• Brand new parts can be sourced by customers as Audi Genuine Parts.
• Audi Genuine Used Parts, on the other hand, are parts that are used but functional and can be resold without remanufacturing.
• Audi Genuine Exchange Parts are Audi Genuine Parts that have failed and been remanufactured. Customers are only given these remanufactured vehicle parts in exchange for a defective part. Ideally, a defective part is exchanged for a remanufactured part. If, in a particular case, it is not directly possible to remanufacture old parts as part of the Audi Genuine Exchange Parts program, they are replaced with new parts (Audi Genuine Parts).

Industrial remanufacturing of defective parts is a key element of the circular economy. The concept extends the different programs offered by the company to promote the principle of the circular economy along the entire value chain. Remanufacturing allows renewed use of a variety of components within selected parts. Audi Genuine Exchange Parts are on average 20 percent less expensive than new parts (Audi Genuine Parts) and are generally available immediately, meaning no wait times for customers.

Audi Genuine Exchange Parts are currently available in 89 markets. The availability of individual product groups may vary depending on the market, model and component. The range includes selected remanufactured powertrain components and electronic parts and has been expanded for certain models and markets to include remanufactured electric motors and Audi virtual cockpits. Remanufacturing is carried out in accordance with defined technical testing and quality processes. Catalytic converters and diesel particulate filters are not used as remanufactured exchange parts but are replaced where necessary. They are transferred to recycling companies so that recoverable material fractions can be reclaimed in accordance with applicable legal requirements and made available for further industrial recycling processes.

Powertrain remanufacturing enters e-mobility

Audi has decades of experience in remanufacturing parts. For more than 70 years, remarkable advances have been made in the remanufacturing of powertrains at the Audi plant in Ingolstadt. This division has already remanufactured more than 7.7 million used powertrains for the Volkswagen Group’s spare parts business, which are also used in other Group brands.

Since 2024, electric motors have also been remanufactured in Ingolstadt, alongside generators, starters and mechatronic components. The goal is to remanufacture around 5,000 electric motors at the company’s main site each year so they can then be used as Audi Genuine Exchange Parts. Only 2.47 kilograms of new material is needed on average to remanufacture an electric motor, for example, to replace seals, screws and bearings with new parts. Essential components such as the housing, rotor and stator as well as the temperature sensor, on the other hand, can be reused. In comparison, approx. 81 kilograms of material is required for a new electric motor.