A Circular Partnership Built to Last
Since 2014, Circulus has partnered with Costa Coffee to develop a market-leading circular solution for its self-service coffee machines.
What began with the repair of a single touchscreen component has evolved into a comprehensive repair and remanufacturing programme. Today, Circulus manages around 72 different component types, refurbishing and redeploying more than 32,000 components every year.
The result is a proven circular model that keeps valuable equipment in active service for longer, reduces reliance on new parts and delivers measurable commercial and environmental value.
The Brief
Costa Coffee operates an extensive estate of self-service coffee machines, requiring a reliable supply of components to maintain performance and minimise downtime.
The traditional linear approach would see failed components replaced with new parts. Together, Costa and Circulus identified an opportunity to do things differently: creating a circular system in which existing assets could be repaired, remanufactured, redeployed and ultimately recovered.
The challenge was to develop a scalable solution that could extend asset lifecycles while delivering the quality, reliability and supply chain confidence required by a major national brand.
The Solution
From Replacement to Recovery
Over 12 years, Circulus has developed a sophisticated circular model designed to maximise value throughout the lifecycle of Costa’s electronic assets.
Failed components are assessed for repair or remanufacture, enabling them to be returned to active service rather than automatically replaced.
The programme also uses data-driven analysis to inform future manufacturing decisions, while component harvesting provides access to critical parts when original components become obsolete or unavailable. At true end of life, assets are safely and compliantly processed to recover remaining material value.
This approach helps Costa:
- Extend the active service life of existing assets
- Reduce new-buy and inventory expenditure
- Strengthen supply chain resilience
- Maintain access to obsolete or unavailable components
- Improve quality and reliability
- Reduce environmental impact
- Recover material value at end of life
Circulus x Costa Coffee: Watch the Film
The Results
747 tonnes CO₂e
By keeping components in circulation, Costa avoids around 747 tonnes of CO₂e emissions every year.
32,000
coffee machine components refurbished and redeployed every year.
72
different component types now repaired or remanufactured.
