150-ton hydraulic press brake retrofit

From challenges to solutions: our retrofit project

Retrofitting industrial machinery is a winning solution for companies looking to modernize their equipment without the expense of purchasing a new one. This process, which combines efficiency and sustainability, extends the life of existing machines, improving their performance and safety. The latest challenge we tackled in our mechanical workshop department is a prime example of success: the complete modernization of a 150-ton hydraulic press brake manufactured in 1996.

The customer's goal was clear: to integrate new features into their aging hydraulic press that would optimize the production process while also ensuring greater operational safety. The main request was the introduction of a foot pedal. Until then, activating the machine required the simultaneous use of a lever and a button, which prevented the operator from moving the workpiece during the pressing process. The switch to a foot pedal freed up the operator's hands, allowing them to handle the workpiece with greater precision and speed.

Another key aspect was the implementation of a more advanced control system. To meet this requirement, we installed a Siemens KTP 700 Basic digital control panel. This new system allows the operator to set and save working parameters, simplifying more complex operations and reducing setup times between jobs. Thanks to this innovation, it is now possible to recall preset programs, ensuring consistent precision and repeatability.

Hydraulic and structural renovation: maintenance and precision
The hydraulic press brake modernization project wasn't limited to the electronics. To support the new features and ensure maximum efficiency, we performed a series of targeted mechanical upgrades. The first step was the installation of a new hydraulic power unit and a new electrical panel, essential for managing the new controls and digital panel.

At the same time, we performed a complete overhaul of the hydraulic system. The cylinder seals and hydraulic hoses were replaced, which, by law, should be changed every eight years to maintain optimal safety standards. The internal inspection also revealed the need for work on the piston. Our technicians found some superficial scratches that, if left untreated, would compromise the seals' seals' tightness, resulting in oil leaks. To resolve the issue, we professionally chrome-plated the entire cylinder, restoring its perfect integrity and functionality.

Finally, to ensure high-precision machining, we milled the worktop, making it perfectly linear again.

The finishing touch was a complete repainting of the press, which now appears not only modern and functional, but also aesthetically renewed.