Maximize Recurring Revenue with Smart Consumables: A Game‑Changer for Machine Builders

In the next five years, digital services are projected to account for 20% of a machine builder’s revenue. If you’re looking to broaden your market and unlock new income streams, consider a paradigm shift: supply your own consumables.

When a machine’s operation relies on consumables, offering a smart consumables service can transform maintenance from a reactive chore into a proactive partnership. By producing or selling consumables that are engineered for your machines, you can reduce downtime and generate complementary product revenue.

Proactive Servicing with Smart Consumables

Smart consumables are non‑durable items—such as cartridges, plastic bags, or bubble wrap—that are consumed during machine operation. Using cloud‑enabled monitoring, you can track inventory levels and notify customers before stock runs low.

In sectors like printing and packaging, missing consumables can halt production and inflate costs. While standard machine tools (e.g., CNC lathes) may have limited scope for this model, there are still opportunities: specialty tools, lubricants, or protective coatings can be offered as part of a smart consumables strategy.

By shifting from reactive to proactive servicing, you can manufacture consumables that align with your machines’ specifications, supply them ahead of time, and eliminate the need for customers to keep large inventories.

Higher Profit, Lower Downtime

Optimised consumables reduce wear and tear, extend equipment life, and cut downtime—benefits that translate into lower costs and higher productivity for your customers.

When you combine proprietary smart consumables with predictive replenishment as a digital service, you create a high‑margin, recurring revenue stream. Customers prefer a single source for both machine and consumable supply, enhancing loyalty and competitive differentiation.

Use Case: Packaging Industry

Imagine supplying custom‑made plastic bags for goods protection and monitoring their usage via the cloud. When a customer reaches 80% usage, an automated alert triggers a replenishment order—before they even notice a shortage.

Would your clients value a just‑in‑time consumable delivery service that removes the worry of stockouts?

Building Your Smart Consumables Strategy

Ready to explore selling consumables with your machines? Begin with a structured plan:

1. Assess Current Practices & Data

• Identify which consumables cause stoppages and gather related PLC and ERP data.
• Analyse statistical correlations to pinpoint critical variables.

2. Prototype & Test

• Conduct in‑house testing on test rigs to validate hypotheses.
• Deploy sensors or PLC parameters, capture data via edge gateways, and store it in the cloud for analysis.

3. Roll Out the Business Model

• Determine how added value will enhance customer satisfaction and revenue.
• Differentiate your machines by offering exclusive consumable services.
• Apply value‑selling techniques to justify an attractive price point.

Consumable Fulfilment Service: Higher Uptime & Recurring Revenue

Deliver high‑quality consumables and a replenishment service to keep your customers running smoothly—and to secure a steady revenue stream for you.

Need help evaluating a consumables strategy for your business? Consult one of our industry experts—no obligation.

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