Compact C-shaped open front presses with optimal accessibility for assembly and press-fitting processes.
Robust double-sided presses in H-frame design for precise forming and joining processes with high forces.
Hydraulic column presses for precise forming, calibrating and cutting of small to large workpieces.
Customized press automation with integrated feeding, control and automated process sequences.
Modernization of hydraulic presses
Existing hydraulic presses today have to perform significantly more than they did at the time of purchase. Increasing requirements for productivity, safety and digitalization often make technological adaptation unavoidable. Retrofit offers a structured way to specifically modernize existing machines and adapt them to current standards.
The mechanical foundation of the press remains intact, while technology, control and safety systems are renewed step by step. This creates a powerful system that can continue to be used economically while meeting the requirements of modern production.
The economical alternative to a new press
Retrofit describes the comprehensive modernization of existing hydraulic presses, in which the basic structure of the machine is retained while technology, control and safety are brought up to date. Through targeted retrofitting, upgrades and conversion, the performance of the system is significantly improved without having to invest in a completely new press.
This creates a technically modern and economically attractive solution that makes effective continued use of existing machines while meeting the highest requirements for productivity, safety and efficiency.
Modernizing a hydraulic press offers economic and technical advantages over purchasing a new machine.
Performance, safety and efficiency are specifically increased while the existing mechanical base is retained. This creates a future-proof solution with reduced costs and downtime.
Modernization is usually significantly more cost-effective than purchasing a new machine, as the massive steel frame of the existing press is retained. An upgrade ensures an economically sensible extension of the service life.
By converting the machine with modern control functions such as position teach-in and program memories, setup times can be significantly reduced and workflows optimized.
In the course of modernization, old motors are often replaced with energy-efficient or speed-controlled drives, sustainably reducing power consumption.
Modern interfaces such as OPC UA enable the press to be integrated into digital production networks. As part of a conversion, production data can be recorded and evaluated in real time.
As the machine remains unchanged in its basic structure, employees benefit from familiar operation. This significantly reduces training time and training effort.
Old presses often no longer comply with current safety standards. Through targeted retrofitting of modern protective equipment and safety controllers, the system is brought up to the current state of the art as part of the modernization.
New displacement measuring systems and pressure sensors as part of an upgrade enable significantly more accurate process monitoring and increase the reproducibility of production.
Spare parts for older controllers are often no longer available. Through upgrades and targeted retrofitting of current components, the long-term maintainability of the machine is ensured.
As the mechanical base of the machine is retained, structural modifications are usually not required, unlike those often necessary with a new machine.
The scope of work depends heavily on the condition of the machine and the customer’s requirements. The following describes a complete conversion as part of modernization.
The machine is completely dismantled, thoroughly cleaned and then repainted in the desired color. As part of the upgrade, it is given an appearance that is both visually and technically as good as new.
The hydraulics are comprehensively inspected and renewed if required. Sources of faults are eliminated and defective components are replaced. As part of the retrofitting, dual-channel operation is often established or monitored valves are added. Pumps are also inspected and repaired.
Seals are renewed and piston rods are repaired and rechromed if required. Complete replacement of the cylinder is also possible as part of the modernization.
A new control cabinet is built and fully wired. The complete cabling to the machine is renewed during the conversion and relaid in a structured manner.
The existing controller is replaced with a modern PLC, for example from Siemens, supplemented by a safety controller, for example from SICK. As part of the upgrade, a new control program is created, including program memory for managing different recipes. For Industry 4.0 applications, interfaces such as OPC UA as well as connections to robots or production data acquisition systems can be integrated.
Old operating and display units are replaced with modern touch panels. Additional control panels or two-hand controls can optionally be added as part of the retrofitting.
Operating modes can be adapted or expanded. Conversion to a key system for access control is also possible.
Outdated safety systems such as light barriers or two-hand controls are replaced with modern solutions. As part of the modernization, the entire machine is inspected from a safety perspective and all danger points are eliminated or safeguarded.
Old displacement measuring systems and analog displays are replaced with modern contactless systems and electronic pressure sensors. Displacement, pressure and force are displayed via the touch panel. As part of the upgrade, additional sensors are added if new requirements make this necessary.
We support commissioning on site and train your employees on the modernized system. Programs are created, adapted and saved to ensure efficient operation.
The following impressions show selected machines before and after modernization by our team. Through technical overhaul, new control technology, modern safety systems and visual upgrading, powerful and future-proof systems are created. The before-and-after images provide a direct insight into our retrofit projects and the possibilities of professional modernization.
Retrofit follows a clearly defined process to achieve an optimal result when modernizing your hydraulic press. Each step is structured and planned with maximum efficiency, safety and system performance in mind.
The current condition of the machine is recorded and analyzed. The customer’s requirements and the options for implementation are discussed in a detailed consultation. This can also take place on site directly at the machine. It is then determined whether the machine will be delivered to us or whether, for smaller scopes, conversion on site is possible.
After commissioning, our engineers move on to detailed planning. We create the new hydraulic and electrical circuit diagrams, design any necessary mechanical adaptations and write the customized control software for your new touch panel. Control cabinets and assemblies are completely pre-assembled in-house.
The actual conversion now takes place. Either the machine is delivered to us or our service team converts it directly on site. The old components are dismantled, the machine is mechanically overhauled and the new modules (hydraulics, control cabinet, sensor technology and cabling) are carefully installed and integrated.
The modernized press is tested intensively. We upload the software, optimize all motion sequences and ensure a smooth production cycle. A key point in this step is the certified safety inspection, including overrun measurement, to guarantee the unrestricted legal compliance of the system.
Before delivery, a joint preliminary acceptance of the machine takes place at our factory. After delivery, the system is professionally commissioned and your employees are comprehensively trained directly on the machine in operation, processes and safety functions.
Here we answer the questions we are asked most frequently. Should you have any further questions, we look forward to hearing from you.
Unfortunately, this question cannot be answered with a blanket yes and always depends on the individual case. In general, however, if the machine can currently be operated safely, the chances are good for a retrofit with reasonable effort.
But even machines that are no longer in operational condition can often be safely retrofitted. We will be happy to inspect the condition of your press and provide detailed advice on site.
The duration depends heavily on the type and scope of the work. For a turnkey complete conversion, you should expect approx. 2-3 months.
The costs also depend heavily on the size of the press and the scope of modernization. As a rule of thumb, however, compared to a comparable new purchase, a retrofit is often up to 50% less expensive, as the massive steel frame does not have to be procured again.
The most effective measure is the retrofitting of a modern, speed-controlled pump drive (servo hydraulics). Unlike old systems, where the motor runs permanently under full load and converts unused energy into heat, a controlled drive only delivers power when the press actually needs it during the cycle. This drastically reduces power consumption and protects the oil.
Modernization offers the opportunity to bring existing hydraulic presses up to the latest technical and economic standards. Together, we develop the right solution for your requirements and support you from analysis through to the successful commissioning of your modernized system.
