Press retrofits – reliable, economical, operator-friendly
Hydraulic and mechanical presses as well as press brakes brought up to the state of the art: a new control system, an optimised operating concept, verified safeguards, and audit-ready documentation (EN/DE).
Economically sound: A retrofit typically costs only a fraction of a new machine – and the machine frame is usually the longest-lasting part of the system.
Why retrofit instead of buying new?
- Preserve the substance: Frame/mechanics (and often hydraulics) are durable. We modernise the safety control system, safeguards, and the operating concept – the core substance remains.
- Familiar asset: Tools, processes, and operators stay compatible – shorter ramp-up.
- Cost & time: Significantly less than a new build; shorter project timelines and planned downtime instead of long lead times.
- Reliability & usability: Robust hardware, clear diagnostics, coherent release logic – less downtime, higher productivity.
How we work (retrofit concept)
- Replace the legacy control entirely – modern safety control system and cabinet (PL e / SIL 3-capable).
- Review & adapt the operating concept – modes of operation, two-hand/setting mode, release logic, clear operator guidance.
- Verify the safeguards – assess function and state of the art; adapt or replace where required.
- Hydraulics (hydraulic presses only) – adapt or renew; cylinders can be overhauled. Implementation with partner Viereck (Elmshorn).
- New documentation & safety evidence – EPLAN P8 drawings, functional description, PL/SIL substantiation, EN ISO 13855 safety distance calculations, validation & acceptance.
Safeguards – approach, criteria, solutions
Approach (always the same):
- Analysis & target picture: hazards, types of intervention (hand/arm/access), material flow, setting tasks, takt/quality.
- Concept decision: choose safeguarding that preserves productivity and makes defeat practically infeasible.
- Mechanics & positioning: posts/mirrors/distances, anti-bypass shielding, clear sightlines.
- Integration into the safety control system: architecture (PL/SIL), safe releases, mode selection, diagnostics and understandable operating concept. On mechanical presses the brake–clutch system is actuated via a press safety valve (state of the art), two-channel and monitored.
- Validation & acceptance: functional tests, stop time/safety distance (EN ISO 13855), protocols, labels, operator briefing.
Typical solutions (derived from the concept):
- Light curtains / multi-beam AOPD – hand/access protection, 14/30/40 mm resolution; EN ISO 13855 safety distance.
- Following systems on press brakes (e.g. PSENvip / AKAS) – tool/sheet detection, safe speeds/zones, defined change-over points (EN 12622).
- Guard doors & interlocks – anti-tamper (ISO 14119), documented release logic; often combined with two-hand/setting release.
By press type – what we actually do
Mechanical / eccentric presses (EN ISO 16092-2)
- New control: contactor/relay logic out → safety control system with clear diagnostics.
- Brake–clutch system: Brake–clutch via two-channel, monitored press safety valve , feedbacks included in the safety diagnostics.
- Stop time & distances: determine exhaust/vent times and stop time → calculate EN ISO 13855 safety distances and document.
- Modes & releases: two-hand (anti-tie-down), setting mode, guard-door logic; interface to automation/robot.
Hydraulic presses (EN ISO 16092-3)
- Modernised control & safety; safeguards as above incl. EN ISO 13855 distance calculation.
- Hydraulics & cylinders: adaptations/renewals and cylinder overhaul together with Viereck (Elmshorn); safe functions two-channel, monitored (e.g. retention/pressure functions).
Press brakes (EN 12622)
- Following safeguarding (e.g. PSENvip/AKAS) or light curtain – depending on tooling, material, and set-up profile.
- Release logic & zones: safe speeds, tool/sheet detection, defined change-over points; documented and validated.
- Usability: setting without incentives to bypass; clear operating guidance.
Economics & substance
- Fraction of a new machine’s cost – while preserving the existing substance.
- The machine frame is typically extremely long-lived – we modernise the safety control system, safeguards, and operating concept (and hydraulics with our partner).
- Back in production faster: shorter project duration, planned downtime windows.
Outcomes in operation
- More stable production thanks to a robust safety control system and clear diagnostics.
- Operator-friendly through a coherent operating concept and unambiguous modes.
- Less downtime, better parts availability, and maintainable routines.
- Safety as a given: PL/SIL evidence, safety distances, validation protocols – audit-ready (EN/DE).
You receive (deliverables)
- Action plan with priorities & budget range.
- EPLAN P8 schematics, functional description, bill of materials.
- PL/SIL evidence, EN ISO 13855 safety distances.
- Validation plan & test protocols, acceptance documents (EN/DE).
- Operator/maintenance briefing plus labels.
Projects (short examples)
Hydraulic press – 600 t (DE)
New safety control system, safeguards adapted → fast, stable production. [Read project]
Eccentric press – robot cell (DE)
Contactor logic → safety control system, new releases → downtime −18%. [Read project]
Press brake (Spain)
Controller replaced, function restored, more efficient operation → fast and cost-effective solution.
[Read project]
Hydraulic press – Müller Weingarten 250 t (DE)
Full retrofit: hydraulics, control cabinet, operating concept → equivalent to a new machine.
[Read project]
Process
- Audit/assessment – machine, goals, documentation.
- Action plan & fixed price – prioritised, transparent.
- Implementation – safety control system, operating concept, safeguards; (hydraulics with partner).
- Commissioning & tests – functions, stop time/distances, releases.
- Validation & acceptance – protocols, Acceptance documents (EN/DE), briefing, handover.
Standards (selection)
EN ISO 16092-2 (mechanical) · EN ISO 16092-3 (hydraulic) · EN 12622 (press brakes) · EN ISO 13849 / IEC 62061 · EN 60204-1 · EN ISO 13855