Turbo remanufacturing – the importance of core recycling
The turbo remanufacturing industry survives and thrives due to the availability of old core, which keeps the repair cycle going. Here, Antony Collins from Melett’s Technical Team explains everything you need to know about the quality and importance of old core.
What is old core? How is it used in the turbo industry?
Old core is a previously used turbocharger that can be used as spare parts to be repaired or remanufactured.
During the turbo remanufacturing process, the old core is disassembled and assessed for damage, with the aim of salvaging those parts with little or no wear/damage. Once done, the unsuitable items are replaced with new components and the turbocharger rebuilt to OE standards and specifications. By remanufacturing, it’s possible to achieve a lower-cost alternative to new units while delivering significant benefits to the environment.
Surcharges are often associated with turbo remanufacturing. These are incentives used to ensure the old core is returned – which helps keep the repair cycle going. When a turbo remanufacturer has the turbo core in stock, they can provide the customer with an efficient and less time-consuming service. With a steady influx of old cores, remanufacturers are able to hold stocks of rebuilt turbochargers so that customers do not have to wait for their failed units to be repaired.
Old core grading and price
There are different grades of old core – the higher the quality, the higher the cost. The grade of old core used can greatly impact the time taken to remanufacture the turbocharger and the number of parts that can be salvaged and reused. The price of old core can also vary broadly depending on the turbocharger model and availability.
Turbo Tip – The lower the quality of old core you purchase; the more time, care and remanufacturing work will be required.
Good quality old core dealers will grade the old core they have available and will explain the potential risks of using a certain, lower quality grade of the core. Each core supplier will have its own grading system, but they all provide an indication of quality. For example:
Good core unit – all parts show little or no signs of damage/ wear
Good core unit with a bad actuator or, a good actuator with play within rotor assembly
Damage to one of the critical components (Actuator, Shaft & Wheel, Compressor Wheel)
Damage to more than one of the critical components (Actuator, Shaft & Wheel, Compressor Wheel)
Good Actuator and one good end-housing (Compressor Housing or Turbine Housing)
Only one good end-housing (Compressor Housing or Turbine Housing)
Quality checks and procedures
It is important to remember that old core is a previously used turbocharger. Time and care must be taken to fully analyse each component within the old core.
The use of good grade old core is important as sometimes you cannot see the damage to the components within. It is only when they are cleaned and inspected that you can really assess the condition of the individual components. Here are some of the ways you can examine each component:
Clean the components – any defects in the components will be more visible
Analyse the component profile – pay attention to detail, have the components warped in any way?
Check the sealing surfaces – especially turbine housing to bearing housing surfaces – are they cracked, corroded or warped?
Impact on the turbocharger remanufacturing industry
When there is a shortage of good quality old core, it can lead to remanufacturers using a poor grade of old core, which in turn leads to extra costs and resources. Low quality cores often require additional remanufacturing or machining processes, such as grinding the shaft or honing the bearing housing. All this adds to the cost of the turbo repair.
If good quality core is unavailable, it is often more economical to supply a new turbocharger. Melett has a range of complete turbocharger units, covering a wide variety of popular applications, which can be used when a good quality core is unavailable to remanufacture. This allows the repair cycle to continue, reduces turnaround times, and ensures customer expectations can be met.
Melett UK will close for the Jubilee bank holiday at 17:00 on Wednesday 01 June and reopen at 08:00 on Monday 06 June. Any orders that are not picked or dispatched before we close will resume preparation when we reopen. If you would like any more information or guidance on the above, please contact our customer care team on +44 (0)1226 320939.
Memorial Day 2022
Melett North America will be closed for Memorial Day on Monday May 30th and will reopen at 8.00 am on Tuesday May 31st.
Melett Polska will be closed for a public holiday on Thursday 16th June and will reopen on Friday 17th June. Any orders that are not picked or dispatched before we close will resume preparation when we reopen. If you would like any more information or guidance on the above, please contact our customer care team on +44 (0)1226 320939.
May Bank Holiday opening hours
Will close 5.00 pm Friday 29th April and reopen 8.00 am Tuesday 3rd May
Will close 4.30 pm Friday 29th April and reopen 8.00 am Wednesday 4th May
PLEASE NOTE -THE ABILITY TO SUBMIT YOUR ORDERS THROUGH THE MELETT WEBSITE HAS BEEN RESTORED
We are delighted to advise full website functionality has now been restored, meaning you can view stock and pricing, add parts to your basket and submit your order via the website. In addition, all turbo/part number searches are fully working.
Until further notice please place your orders by 2.30 pm and we will endeavour to dispatch the same day dispatch.
We will keep you updated as we navigate through the remaining internal connectivity issues, we have dedicated teams working round the clock to resolve any remaining issues as quickly as possible.
We, at Melett, would like to stress our gratitude for your continued patience and support throughout this difficult time.
Please note you can now view your pricing on the Melett website.
We appreciate this is not a complete solution at this stage, however, please be assured our internal website and IT teams remain focused on reinstating the stock availability function.
We cannot stress enough that we are doing everything we can to reconnect our internal system, and we will restore full website functionality as soon as possible.
If you experience any problems whilst ordering online, please do not hesitate to contact:
W związku z awarią sieci telefonicznej prosimy o kontakt na telefon komórkowy: Damian 512 372 612; Kasia 511 372 612
Melett UK will be closed on Monday 29th August and will reopen at 8.00am on Tuesday 30th August.
Any orders that are not picked or dispatched before we close on Friday 26th August will resume preparation when we reopen. If you would like any more information or guidance on the above, please contact our customer care team on +44 (0)1226 320939.
Melett Polska will be closed for a public holiday on Friday 11th November and will reopen on Monday 14th November.
Any orders that are not picked or dispatched before we close on Thursday 10th November will resume preparation when we reopen. If you would like any more information or guidance on the above, please contact our customer care team on +44 (0)1226 320939.
Queen Elizabeth II state funeral - Monday 19th September
Melett UK will be closed on Monday 19th September for the state funeral of Queen Elizabeth II . Melett will be joining people and businesses across the country in reflecting on Her Majesty's incredible contribution and enduring legacy.
Melett North America and Melett Polska will remain open as normal.
Easter opening hours
Melett UK - will close 17:00 Thursday 14 April and reopen 08:00 Tuesday 19 April Melett Polska - will close 16:30 Thursday 14 April and reopen 08:00 Tuesday 19 April Due to essential maintenance, the Melett website will be temporarily unavailable on Thursday 14 April from 17:30 to 19:30. We apologise for any inconvenience caused.
Due to essential maintenance, the Melett website will be temporarily unavailable on Friday 25 February from 18:00 to 20:00 (GMT). We apologise for any inconvenience caused.
Planned maintenance – Thursday 24 March 2022
We will be undertaking planned maintenance on our internal systems this evening between 17:00 and 20:00 GMT, which will affect some website functionality.
We aim to keep disruption to a minimum and the website will remain online. However, we will need to temporarily disable online ordering during this time.
Thank you for your understanding.
We are undertaking essential maintenance this weekend (February 19-20) and some of our website services may be unavailable at times. We apologise for any inconvenience this may cause.
- Due to essential maintenance, the Melett website will be temporarily unavailable on Friday 28 January from 18:00 to 20:00 (CET). We apologise for any inconvenience caused.
Festive opening hours
- Melett UK Will close 5:00pm Thursday 23rd December and reopen 8:00am Tuesday 4th January
- Melett Polska Will close 4:30pm Thursday 23rd December and reopen 8:00am Monday 3rd January
- Melett North America Will close 5:00pm Thursday 23rd December and reopen 8:00am Monday 3rd January
Please note: Due to essential maintenance the Melett website will be temporarily unavailable on Friday 10 December from 5:00PM (CET) to 11:00PM (CET). Apologies for any inconvenience caused.
Please note; Unfortunately, we are experiencing processing delays for all orders which may result in delays in shipping. If possible, please confirm orders at your earliest opportunity to help minimise disruption to our normal high standards. Please accept our apologies and rest assured that we are working hard to resolve the issue.
Melett Poland will be closed for a Public Holiday on Thursday 11th November. Any orders that are not picked or despatched on Wednesday 10th November will resume preparation when we return on Friday 12th November.
Melett Poland will be closed for a Public Holiday on Thursday 6th November. Any orders that are not picked or despatched on Wednesday 5th November will resume preparation when we return on Friday 7th November.
Melett will be closed for a Public Holiday on Thursday 11th November. Any orders that are not picked or despatched on Wednesday 10th November will resume preparation when we return on Friday 12th November.
Melett will be closed from 5 pm on Wednesday 24th November until 8 am on Monday 29th November for the Thanksgiving holiday
Online ordering now available
In addition to viewing inventory levels and pricing, you can now place orders directly from our website. Download our user guide below to help you get started.