In 2023, over 328,000 end-of-life notifications for electronic components were recorded worldwide – a third of these without any prior warning. By 2025, the figure had already risen to around 620,000. Semiconductors are now discontinued after 7 to 10 years, whilst the devices in which they are used remain in service for 10 to 20 years – and significantly longer still in the case of vehicles subject to aftermarket requirements.
This gap cannot be dismissed; it can only be bridged. Those who ignore it are faced with a choice between two costly options: developing a new solution or facing production downtime. Those who bridge the gap must ensure that a component remains just as functional after years in storage as it was on the first day – and that is precisely where the real risk begins.
Sources: Z2Data, EOL Trends 2023/2025
The storage of electronic components requires a thorough understanding of the specific requirements of each component and how it interacts within the overall system.
Sascha Munsbeck, Head of Production, btv technologies
A vehicle lasts for two to three generations of semiconductors. The all-electric ID.7 contains around 18,000 semiconductors – each one a potential point of failure.
If a replacement chip is missing in the field, it is not the component itself that is the problem. It is the entire control unit – and, in the worst-case scenario, the vehicle itself.
Why does a component in storage deteriorate without anyone noticing?
Four mechanisms are at work simultaneously and invisibly: humidity causes oxidation at the connections; ESD damage remains latent until the component is deployed in the field; components continue to age chemically even whilst packaged; and without a power supply strategy, there is a risk of capacitor ageing and cold solder joints. The damage does not become apparent during storage, but only years later – once the component has been installed.
Why unprotected storage merely shifts the risk
Many manufacturers simply store control units or microchips on standard shelves when they are due to be phased out – without any protection against humidity, ESD or temperature fluctuations. Whilst this saves costs in the short term, it merely postpones the risk to a later, uncontrollable point in time. Four mechanisms ensure that a component ages in storage without anyone noticing:
Humidity causes oxidation and diffusion at the component terminals – resulting in solderability issues that often only become apparent during subsequent installation. ESD damage frequently takes the form of latent defects: invisible at the time of storage, but the cause of premature failures in the field. Components continue to undergo chemical ageing even when packed and powered off – ‘keep it dry’ alone is not enough. Furthermore, without a power supply strategy, control units fitted with electrolytic capacitors face the additional risks of capacitor ageing and cold solder joints – a risk that can be specifically avoided through power cycling at 12- to 24-month intervals.
What this means for your component, your control unit and your end product
The effect extends throughout the entire assembly: a microchip is mounted onto a circuit board; the assembled circuit board, housed in a casing, forms the control unit which is then installed in the end product. If the component is protected in good time, all the assemblies above it remain stable. If protection is lacking, the chain tips in the opposite direction: a missing microchip renders the printed circuit board inoperable; a faulty printed circuit board renders the control unit inoperable; and, in the worst-case scenario, a faulty control unit renders the entire end product inoperable.
This is precisely where btv technologies’ standard storage differs: it is already ESD-safe, climate-controlled and FM Global fire-rated – the standard basic safeguards that unprotected storage without any concept in place undermines from the outset.
Sources:
- Moisture, oxidation, solderability: JEDEC standard for Moisture Sensitivity Level (MSL) classification
- Delayed ESD damage: ESD Association, ‘EOS/ESD Fundamentals’; Texas Instruments, Application Note: Electrostatic Discharge (ESD)
- Capacitor ageing: Kyocera, Safety Application Guide for Multilayer Ceramic Capacitors
Our long-term storage goes beyond the requirements of DIN EN IEC 62435 – with bespoke protective measures, additional checks and digital monitoring. Where the standard sets out a minimum requirement, we deliberately set the bar higher – in a way that is documented and verifiable, not merely claimed.
At the heart of the process is a fixed repacking cycle: every two years, the components are repacked on a regular basis – well before the three-year shelf life of the moisture barrier bags expires. This safety margin ensures that there is never any risk posed by an ageing protective bag.
- Smart storage: Identity, quantity and original packaging are checked and secured for the long term, with additional protection provided by ESD and moisture barrier bags.
- Controlled storage: Air-conditioned, separate ESD zones. Distributed storage locations available on request for maximum reliability.
- Power supply & functional testing: Regular, scheduled test cycles, fully documented – for maximum operational reliability.
- Intelligent repacking: Routine visual inspection, moisture checks and repackaging on a fixed two-year cycle – documented and auditable.
- Digital monitoring & reporting: Up-to-date data and full traceability of stock, storage cycles and reports – accessible at any time.
Independent validation
Our long-term storage is tested by independent institutes: at our request, the Fraunhofer Institute for Silicon Technology (ISIT) has examined SMD components that have been in storage at btv technologies since the year 2000. Even after additional artificial extreme ageing – dry heat up to 155 °C for 16 hours, and humid heat at 85 °C and 85 per cent relative humidity for 24 hours – no wetting defects were observed in the reflow soldering process. The institute also confirmed a positive prognosis for a further ten years of storage.
Customer case study: 86,500 control units, 0 field failures
A Tier 1 supplier was faced with a classic obsolescence problem: a 15-year statutory obligation to supply spare parts for a vehicle control unit, but the microcontroller used in it had already reached end-of-life after just 7 years. This affected 86,500 control units across two product variants. The redesign option would have cost 700,000 euros.
The approach chosen: end-of-life production in accordance with EN 62435+, storage in a nitrogen atmosphere with repackaging every two years, a power-cycling concept to counteract capacitor ageing, and on-demand delivery throughout the full 15-year period.
The result after 15 years: zero field failures, cost savings of around 40 per cent compared with the redesign option, and all IATF 16949 audits passed – without a single complaint regarding the supply chain.
Anonymised customer case study, automotive sector.
The sustainability lever that hardly anyone factors into their valuations
Globally, around 62 million tonnes of electronic waste were generated in 2022, with a forecast of 82 million tonnes by 2030 – an increase of 33 per cent over eight years. Only around 22 per cent of this is formally recycled. The vast majority is lost without being utilised.
However, the real lever for change lies not at the end of the life cycle, but in the middle: 77 to 87 per cent of emissions from digital technologies arise before the actual use of the products, during manufacture and in the supply chain (RIfS Potsdam) – and in the case of electronics manufacturing in particular, more than 85 per cent (Fraunhofer IZM via Silicon Saxony). Every component that can be reused from long-term storage, rather than being produced from scratch, avoids precisely this largest source of emissions.
Is long-term storage required by law?
Not as a separate obligation, but as a consequence of several regulatory frameworks: since July 2024, the ESPR has required longer product lifespans; the CSRD requires the disclosure of Scope 3 emissions; and the LkSG requires traceability within the supply chain. The Cyber Resilience Act also requires seamless traceability when integrating third-party components (Section 13(5)) – long-term storage with full traceability provides the data basis for this, without itself being “CRA-compliant”.
Component protection is no longer merely a voluntary additional service, but is governed by several legal frameworks:
- ESPR (EU) 2024/1781: has required, since July 2024, the extension of product lifespans and recyclability.
- CSRD: mandates the disclosure of material Scope 3 categories, including purchased goods.
- LkSG: requires due diligence and traceability throughout the supply chain.
- CRA-relevant traceability: The Cyber Resilience Act requires manufacturers to exercise due diligence when integrating third-party components (Article 13(5)) – seamless traceability of components right down to the firmware version is a prerequisite for this, not an optional extra.
btv traceability documents at least 20 years’ worth of process data across all storage stages – digitally, auditable and accessible at any time.
btv LONGEVITY® – Premium protection for the most demanding requirements
For components where standard storage is not sufficient: btv LONGEVITY® is the premium add-on for long-term storage from btv technologies – developed for components with particularly high requirements for protection against corrosion, diffusion and contaminants throughout the entire storage period, up to 50 years. In addition to the LZL standard, a sacrificial material is used to specifically protect plastics against corrosion.
We’ll be happy to discuss which components benefit from btv LONGEVITY® and how it can be integrated into your existing storage strategy.
Who benefits from long-term storage?
For anyone who needs to keep electronic components operational for years: OEMs and Tier 1 suppliers with long spare parts obligations (automotive, aviation, defence), industrial and energy companies with systems that outlast the semiconductor lifecycle, medical technology firms with stringent certification requirements, and any company with a ‘last-time-buy’ strategy – regardless of size.
- OEMs and Tier 1 suppliers: with long spare parts obligations (automotive, aviation, defence).
- Industry and energy: with systems that operate for significantly longer than the underlying semiconductor life cycle.
- Medical technology: with high certification and verification requirements for every component replacement.
- Companies with a ‘last-time-buy’ strategy: which need to reliably bridge the gap until their final purchase.
- Companies of all sizes: from OEMs to Tier 1 suppliers and specialist firms, right through to medium-sized enterprises.
A typical project timeline
The situation is usually the same: a component is about to be discontinued, but the obligation to supply spare parts still runs for years. This is how the process works with btv long-term storage:
- Risk analysis. Which components are affected by discontinuation, and how long must supplies last?
- Quantity calculation. How many units are required for the remaining service life – based on a BOM and demand analysis?
- Storage. Checking identity, quantity and original packaging; additional protection via ESD and moisture-barrier bags; storage in climate-controlled, ESD-safe zones.
- Ongoing protection cycle. Repacking every 2 years for all components. For assembled control units, additional power cycling every 12 to 24 months to prevent capacitor ageing – bare microchips without electrolytic capacitors do not require this additional procedure. Comprehensive documentation covering both protection stages.
- Delivery on demand. Call-off orders throughout the entire contract period, with full traceability for every movement.
This ensures your component remains operational for years – without you having to bear the storage risk yourself.
At a glance
- Stable prices, guaranteed availability: Long-term predictability guaranteed.
- Maximum protection – even on a temporary basis: Ideal for short-term storage too.
- Audit & compliance-ready: Certified quality, ready for OEM inspections.
- Suitable for businesses of all sizes: OEMs, Tier 1 suppliers, specialist firms & SMEs.
- Validated by Fraunhofer ISIT since 2000: no wetting deficiencies following extreme ageing.
- Around 6 million components protected: with a measurable reduction in CO₂ emissions.
FAQs – direct, honest, to the point
Our solutions offer more than just the provision of components: key elements include transparency, seamless traceability, audit compliance and exclusive quality assurance that goes beyond statutory requirements. You receive bespoke additional services such as power supply and functional monitoring of your control units – for maximum operational reliability.
At btv technologies, your stored components are protected against loss, damage and storage risks through comprehensive safeguards and bespoke insurance schemes. This goes far beyond a traditional warehousing service: As part of our btv TAK® model (Component Logistics as a Service), we even offer you complete supply chain protection – including active stock monitoring, flexible allocation and, where required, obsolescence management with strategic stockpiling and risk-minimised processing.
You can find more information on btv TAK® – Component Logistics as a Service here.
We have been successfully storing electronic components for our customers since 2006. Over this period, we have built up extensive expertise – ranging from long-term storage and obsolescence management to bespoke solutions tailored to a wide variety of industry requirements. This long-standing experience makes btv one of the most reliable partners when it comes to security, compliance and flexibility in all aspects of your component storage.
btv technologies provides you with comprehensive support in the areas of last-time-buy and obsolescence management. You benefit not only from bespoke long-term storage, but also from flexible stocking, strategic reserve stocks and forward-looking procurement support.
With our btv TAK® model, you can manage all component flows digitally, at no cost to your margins and with full transparency – whether for stock management, one-off special parts or company-wide supply security.
Discover how btv TAK® makes your supply chain management future-proof – further information is available on our page about Component Logistics as a Service.
Find out now whether your component will still be suitable for production in 15 years’ time
The difference between stock management and value retention only becomes apparent after several years – but it can be calculated today.
We’ll work through with you which components in your organisation are affected by product discontinuation, how long your current stock needs to last, and what a protection strategy for this might look like.
