Air Systems are a crucial part to mechanical presses and to a lesser degree to servo hydraulic presses. Safety for press operators depends on proper maintenance and operating systems. If any part of the air system is leaking or not functioning properly, it should be reported to the maintenance supervisor immediately.
All presses should be equipped with a minimum of electronically monitored air pressure switch that will prevent press operation if air pressure is too low.
Failure to make sure air systems are operating and set to correct pressures can result in major damage to other parts of the interrelated press drive systems (see #2 air counterbalance, #3 clutch & brake and #4 connection points).
Air Counter-Balance Systems are a crucial part to mechanical presses. If any part of the air system is leaking or not functioning properly, it should be reported to maintenance supervisor immediately.
All presses should be equipped with an ACB pressure gage, adjustment regulator and a graph chart that indicates air pressure required to upper die weight. Each time a new die is loaded the ACB pressure should be reset. Good practice is to mark upper die to show correct measured weight.
Failure to make sure ACB system is set to correct pressures will result in major damage to other parts of the press drive system (see #4 connection points).
DRY Air Clutch & Brake Systems are a crucial part to mechanical presses. If any part of the air system to the CB System is leaking or not functioning properly, it should be reported to maintenance supervisor immediately.
Dry clutch and brake units are workhorses of the stamping floor, ensuring precise starts and stops that protect operators, dies, and parts. Yet, behind their productivity lies a silent, persistent threat: improper maintenance. Overlooking clutch/brake upkeepâeven for a weekâcan silently degrade lining plates, decrease stopping accuracy, and cause dangerous operational delays. Many operators assume these machines can handle a little grime or ignore creeping noises, not realizing minor issues rapidly escalate into catastrophic failures or expensive downtime.
Consider the ripple effects of neglectâyour dry clutch/brake system falls out of adjustment. Pressure settings drift below spec. Instead of smooth, positive engagement, grinding starts and erratic stops risk operator safety and destroys tooling. Plate linings overheat and develop cracks after a single double-shift in this condition. The air supply system accumulates moisture and sludge. Without weekly draining, water vapor corrodes air passages and valves, reducing response time and increasing the chance of clutch slip. Suddenly, your once-precise press is unpredictable and dangerous, requiring costlier emergency repairs and risking OSHA citations for unsafe operation.
Month after month, productivity falters, then the system fails at the worst possible timeâmid-run, with a rush order and an impatient customer waiting.
Prevent disaster with a comprehensive dry clutch/brake maintenance regime:
The cost of disciplined routine checks shrinks in comparison to lost production, tooling wear, orâworst of allâoperator injury. With vigilant dry clutch and brake unit upkeep, presses stay safe, responsive, and reliable, maximizing uptime and minimizing life-cycle costs.
Wet clutch and brake systems are designed for high-output environments, offering smooth, heat-resistant performance under punishing duty cycles. However, this advantage comes with a tradeoff: complex hydraulics and lubrication demands.
Neglected oil levels or unmonitored contamination quietly undermine the system's thermal stability. Most breakdowns in wet units trace back to lapses in oil cleanliness, incorrect fluid volumes, or infrequent component inspectionsâissues often overlooked in the crush of daily production.
Imagine a scenario where oil is not checked for weeks. The once-pristine fluid becomes laden with fine metal shavings or moisture, reducing its cooling and lubricating power. The clutch and brake linings, deprived of adequate cooling, begin to overheat. This invisible degradation warps plates, bakes on residues, and destroys proper clearances. Oil-starved components grind and chatter, friction increases. When an operator hits the emergency stop, the slide hesitatesâthen jerks to a sloppy halt, risking part quality and operator safety. Persistent neglect forces the entire system offline for an expensive rebuild, stranding your orders and damaging your reputation.
Guard against these failures with a robust wet clutch/brake maintenance protocol:
Routine care for wet clutch and brake units means minimal downtime, reduced running temperatures, and years of extended life for pressing equipment. Protect your investment, your personnel, and your throughput with systematic attention to oil quality, system hygiene, and pressure accuracy.
Dry and wet clutch/brake units are linchpins of stamping press safety and performanceâand their reliability relies on nothing more or less than consistent, informed maintenance. Whether keeping air dry and linings pristine, or ensuring clean, cool oil continuously lubricates and cools, a structured program is the only path to sustained uptime and pressroom confidence. By confronting problems before they start and agitating the effects of neglect, you guarantee not just machinery longevity, but a safer, more productive shop floor.
In the fast-paced world of metal stamping, achieving precision and avoiding costly equipment downtime hinges on maintaining all crucial connection points, pressure systems, and settings in your mechanical press drive. However, many shops unknowingly risk catastrophic failures and expensive repairs by overlooking a few critical factors: correct air counterbalance (ACB) and hydraulic overload protection (HOLP) pressure settings, and the dangerous effects of reverse or snap-thru tonnage during blanking operations. Improper adjustments or lack of awareness in these areas can damage your equipment, threaten operator safety, and chew away at profits.
Too often, a high-output stamping line grinds to an unexpected halt. The culprit? A simple mistake in ACB or HOLP pressure settings, or a shockwave from reverse tonnage as sheet metal is blanked. If the ACB pressure is set too low, the immense weight of the upper die and ram isn't fully counterbalanced, translating every rapid slide stroke into a harsh, hammering effect on your press's drive connection points. This impact wears bushings, cracks pins, deforms couplings, and can even distort the slide itself. Set the ACB pressure too high, and your main motor works overtime, increasing amp draw, overheating, and driving up your power bills while over-stressing the drive components.
Further complicating matters, failure to set the proper HOLP pressure exposes your press to dangerous overloadsâpress damage and die cracks can cost tens of thousands to fix. Worse, incorrect settings for specific jobs, or neglecting to adjust for dynamic pressures at higher SPMs, only amplify risk.
But nothing tests the press like blanking. When a blank separates from the coil, energy stored in deformation is released in a split second, translating into reverseâor snap-thruâtonnage. The shock travels back through your drive train, jarring every connection: the motor and flywheel coupling, the clutch assembly, the crankshaft, and ultimately, the ram. Without proper pressure settings and robust shock absorption, this force rattles down your entire mechanical linkage. Gears loosen, bearings fail, the slide can go out of alignment, and soon, fine-tuned press precision is lost along with time, money, and possibly your reputation.
Protect your assets with a thorough understanding and vigilant maintenance of every connection in your press drive system. Here's how:
Implementing these practices doesn't just prevent sudden failures; it extends the lifespan of your press and tooling, boosts ROI, and maintains the high accuracy and repeatability your customers expect. Put simply: Know your connections, respect the power of pressure settings, and neutralize the risk of reverse tonnage. With the right strategy, you can stamp out unnecessary downtime forever.
Press control systems should be designed for the highest safety for operators of presses. No one should operate a press unless they have been fully training and read the press manual and this Maintenance Tip document.
Point of operation guards are the sole responsibility of the end user. All point of operation guards should be check at a minimum weekly. Every effort to prevent access to the pinch point area should be made.
Your press is a workhorseâevery cycle, relay, and terminal in its electrical system keeps your operations on track. But much like the visible wear on mechanical parts, unseen electrical weaknesses can emerge: corroded connectors, loose wires, poorly grounded enclosures, or moisture hidden behind sealed doors. If left unchecked, these invisible threats can lead to production losses, unexpected downtime, even hazardous failures that put your team and facility at risk.
Imagine an operator at a standstill, the press locked out by a relay that failed due to undetected moisture intrusion. Or worse, power surges tripping sensitive controls, shutting down output in the middle of vital production runs. Uninspected electrical enclosures can accumulate dust or debris, causing local overheating or short circuits. Without strict weekly functional testing, your team may not uncover issues until they cause a catastrophic operational issueâor a safety incident. Expensive repairs, lost time, compromised product quality, and potential injury now loom over what could have been a thriving, efficient process.
Too often, these breakdowns can be traced to lapses in routine press electrical inspection and failure to respect safety protocols. Many operations rely on mechanical checks, neglecting the unique risks of complex electrical systems and controls. Allowing untrained personnel or unauthorized modifications magnifies the risk, introducing hazards and voiding critical warranties.
Protect your press, your people, and your productivity: implement a structured, methodical approach to press electrical maintenance and enclosure inspection.
Final Caution: Don't Gamble with Electrical Risks Neglecting press electrical maintenance or letting unqualified hands tinker with systems is a recipe for disaster. Protect your investment and your workforce by committing rigorous, scheduled inspection, testing, and strict control of all electrical maintenance activities.
Unseen electrical issues are ticking time bombsâbut with the right discipline and respect for proper procedures, you can ensure your press' electrical heart keeps beating safely and reliably for years to come.
Upgrading to I-PRESS Controls is not just an equipment change, it is a strategic move towards an agile, data-driven, and future-ready pressroom. Harness the latest in hardware and software, redefine productivity, ensure seamless connectivity, and gain a competitive edge. Bring the benefits of smart technology, real-time insight, robust service, and reliable platforms to your operation today with I-PRESS Controls.
Visit our I-PRESS Simulator for hands on demo > https://www.sutherlandpresses.com/i-know?tab=ipress&sec=6a
Want to know more, email I-PRESS@SutherlandPresses.com
In today's high stakes manufacturing environment, stamping and forming operations depend heavily on stringent tolerances, repeatable accuracy, and minimal downtime. Yet, amidst the rush to meet production quotas and drive down unit costs, many metal stamping operations overlook a critical, often underestimated facet of their machinery: the integrity of press slide guidance and the gibs that support it. This neglect, compounded by an insufficient understanding of parallelism, can lead to catastrophic outcomes for die life, product quality, and plant productivity.
The cost of overlooking these fundamentals is not always immediate. Presses may seem to run acceptably for months, producing parts "within spec." But over time, subtle issues begin to emerge. Dies start to show signs of premature wear. Parts drift out of tolerance, causing rework or even scrap. Press maintenance intervals shorten, and unplanned downtime becomes a recurring nuisance. Teams may attempt to compensate by adjusting shut heights or tweaking die alignments, often treating symptoms rather than solving the root cause.
Operational managers and maintenance engineers feel the frustration as service ticket volumes rise, customer satisfaction dips, and production schedules get threatened. The root of these headaches? Often, it is the failure to appreciate and maintain precise slide guidance, adequately fitted gibs, and parallelism between the press slide and bolster â all essential for prolonged die life and consistent product output.
Let's paint a picture: A progressive die costing hundreds of thousands is installed in a production press. Initial test runs look good, but over weeks, subtle burrs begin appearing on the parts. The maintenance team investigates and finds the die unexpectedly worn and misaligned.
What happened? The slide guidance system, designed to keep the slide moving precisely along its intended path, has developed excessive clearance due to worn or poorly adjusted gibs. This minute play allows the slide to tilt or yaw, breaking parallelism with the bolster. Even a misalignment of just 0.001 inches can start a cascade of negative effects.
Ramifications include:
The scenario worsens as operators compensate for inconsistent part quality. They may over-tighten shut heights or manually reposition dies, covering up fundamental mechanical misalignments. This band-aid approach often leads to product recalls, costly press rebuilds, and â most damaging of all â a loss of customer trust.
Studies have shown that misalignment between the press ram and bolster can reduce die life by 25% or more. In severe cases, improper slide guidance or gib setting can nearly halve expected tooling longevity. Given that dies represent one of the most significant investments in a stamping operation, the economic consequences are staggering.
Moreover, such issues are seldom isolated. Gib wear and loss of parallelism directly jeopardize not just a single die, but every tool the press runs. Productivity sinks as the maintenance team struggles with chronic, recurring die failures and unplanned stops. The company's reputation suffers in the market due to inconsistent shipments and reduced product quality.
Sustained manufacturing excellence requires more than advanced machinery; it demands a disciplined approach to the fundamentals of press mechanics. Ensuring optimal press slide guidance, gibs, and parallelism is not a set-and-forget task, but a continuous cycle of measurement, adjustment, and improvement.
At the heart of any mechanical or hydraulic press lies the slide guidance system, typically consisting of gibs (wear plates) meticulously fitted to guide surfaces. Modern presses employ full-length, adjustable gibs on all four corners of the slide, minimizing any lateral movement (clearance) and controlling off-center loads.
Best practices include:
Gibs must be set with precise clearanceâtight enough to control movement but not so tight as to induce excess friction or heating. Gib wear, if unchecked, introduces camber, pitch, or yaw, degrading parallelism.
Key steps:
True parallelism between the slide and bolster is critical. Even with robust gibs, if the ram sits out-of-parallel due to mechanical wear, improper slide adjustment, or foundation settling, dies will bear the brunt.
Implementation should involve:
Technical systems only perform as well as the people who maintain and operate them. Manufacturers must:
Utilize digital service tickets, inspection forms, and trending data to track the condition of press slides, gibs, and parallelism over time. Structured documentation not only ensures compliance but builds a robust knowledge base to predict issues before they escalate.
The essence of high-performance stamping and forming is not just in technology, but in the disciplined application of age-old principlesâprecision slide guidance, thoughtful gib setting, and rigorous monitoring of parallelism. By systematically improving these fundamentals, stamping operations can preserve die life, ensure consistent part quality, minimize costly downtime, and secure the company's reputation for reliability and excellence.
Leaders in pressroom innovation recognize that investing in core press mechanics pays dividends every day the line runsâprotecting the company's most vital tooling assets, upholding production commitments, and safeguarding the bottom line. The path to a new era of manufacturing excellence is paved as much by attention to foundation as by embracing innovation: stability, predictability, and longevity of dies and presses are never accidents; they are the result of conscientious attention to the details that few see but all depend on.
Excellence through continuous alignment, longevity through disciplined maintenance, and the promise of future generations pressed into every part produced.
In every stamping facility, the hum and thump of a mechanical press signals productivity. But beneath the steady rhythm runs a dangerous risk that's often overlooked: overloads. An overloaded press, whether from a jammed die or a miscalculated setupâcan bring production to a grinding halt, inflict hidden damage to your machine, and lead to repair costs that slash directly into your bottom line. Yet, it's not just the rare catastrophic overload you should be worried about. Minor repeated overloads and overlooked press adjustments slowly wear your equipment downâa problem that can lurk for months before revealing itself in the form of drive train & slide adjustment mechanism failures, excessive downtime, or costly rebuilds.
Many companies rely on their operators to catch early signs. But overloaded conditions happen in an instant, often before anyone has a chance to intervene. And with today's high-speed production demands, even a brief misstep or unnoticed jam is more than enough to unleash forces your press drive system was never designed to withstand.
Here's where it gets dangerous. Hydraulic Overload Protection (HOLP) systems are designed as a last line of defense, but like any system, they're only effective if maintained and used correctly. Too often, what should be a safety net becomes a liability due to improper maintenance, incorrect setup, or simple inattention:
Each of these mistakes, whether from misunderstanding or a busy production schedule, can result in exactly what HOLP is meant to prevent: expensive downtime, ruined tooling, or irreversible press damage. Consider a real scenario where a neglected tank was routinely topped off to the brimâso when an overload hit and oil had nowhere to evacuate, seals burst, damage spread to the suspension points, and that press spent weeks out of commission.
The good news is safeguarding your pressroom isn't about complicated routines or expensive upgradesâit's about consistent adherence to a few proven best practices:
Hydraulic Overload Protection keeps your press (and profits) safe by instantly releasing pressure when forces exceed 110 percent of capacityâfreeing stuck dies, stopping the press drive, and preventing catastrophic mechanical failure before it starts.
Always check oil level with the press in the ready-to-run state and system pressurized. The oil should rest at the midpoint of the sight gauge, not at the top. This gives space for hydraulic fluid to evacuate from the HOLP pistons during an overload. If the tank is overfilled, there is nowhere for displaced oil to safely goâleading to blown seals and system failure exactly when you can least afford it.
Never adjust the HOLP system pressure above (or below) the manufacturer's recommendation. Changing the setting risks is damaging not only your press drive system but can invalidate warranties and set you up for undetected, cumulative damage from overloads.
Reserve time every week to operate the HOLP system, confirming all valves and pistons move freely and the gauge readings are correct. One simple method: place a dial indicator between the bolster and slide, activate the release, and verify proper upward movement. Record changes and address any anomalies immediately.
Set ACB pressure to accommodate the slide and upper tooling weight for every new job. Keeping this adjustment correct keeps snap-back (reverse tonnage) in check and further protects your drive train and tooling from wear.
If bolster space is at a premium, look for presses with hydraulic dampers built into side frames. This ensures that snap-through protection does not come at the expense of available workspace.
A hydraulic overload event will happenâit's a matter of when, not if. But consistent, correct maintenance and operator vigilance turn HOLP from an 'expensive option' into an essential insurance policy. By never overfilling the tank, following weekly tests, and refusing to 'tweak' setup pressures, you guarantee your press can handle overloads safely, extending machine life, protecting dies, and keeping the heartbeat of your production floor steady.
When your next job runs flawlessly, remember it's not luckâit's the result of understanding, prevention, and disciplined maintenance. Keep your HOLP system healthy, and your press will keep your business strong.
This section applies to traditional hydraulic presses and our Servo Hydraulic Presses. It is critical that the oil in your press fluid management system is clean to prevent damage to valves, cylinders and all components that the oil encounters. Temperature control is also important to prevent breakdown of oil viscosity and lubricating properties.
Hydraulic presses are the backbone of manufacturing plants, metal stamping, and fabrication shops around the globe. Their power and reliability fuel production lines and keep businesses moving. Yet, for all their robust engineering, the hydraulic press has a silent Achilles' heel: the fluid management system.
Across the industry, overlooked or neglected hydraulic fluid management leads to catastrophic breakdowns, poor press accuracy, premature component failure, and skyrocketing repair bills. Fluids deteriorate. Filters clog. Seals harden. Microscopic contaminants find their way into critical clearances, shortening equipment life and risking workplace safety. These failures do not happen overnightârather, they are the predictable result of poor inspection practices, infrequent maintenance, and a lack of proper documentation.
The root consequence? Unexpected downtime, production delays, and loss of profits, not to mention the costs of emergency repairs and potential workplace accidents. Even the best-designed presses will suffer if their fluid management systems are neglected.
Let's paint a realistic picture: Imagine a high-output facility relying on hydraulic presses to meet tight deadlines. Production is humming, but hidden within the hydraulic reservoirs, contaminants have started to build up. The fluid, dark and viscous, passes through worn filters barely clinging to life. A technician, rushed by schedules, skips a scheduled fluid analysis. The reservoir breather shows signs of moisture ingress, but no one checks it.
Suddenly, system pressures drop. The press shudders and slows, then locks up entirely. Inspection reveals extensive scoring on cylinder walls and galled pump surfacesâa clear sign of abrasive contamination and fluid breakdown. Metal fines and debris circulate unchecked, damaging valves and actuators before the source is even identified. The cost to repair the press runs into tens of thousands of dollars, and customer delivery dates are missed. Overtime wages soar as shifts scramble to recover. Management demands answers: How could this have been prevented?
This scenario is far too common. Hydraulics press fluid failures rarely give early, obvious warning signs. Subtle changesâslower cycle times, increased noise, slightly elevated temperaturesâare the blips before the storm. When these are missed due to poor inspection or sloppy maintenance, the results are disastrous.
But that's not all. Hydraulic fluid leaks can be just as insidious. Even minor leaks, left unaddressed, can drastically lower system efficiency, introduce air into the hydraulic loop, and pose slip hazards around the work area. Over time, leaks also mask larger component failures and waste valuable resources. Environmental and safety violations can quickly follow, exposing companies to fines and litigation.
Without a disciplined and proactive approach to hydraulic fluid management, every press in your operation is sitting on a ticking time bomb.
The good news: Catastrophic press failures, costly downtime, and poor output quality are preventable. Instituting a robust inspection and maintenance routine for your hydraulic press fluid management system is not optionalâit is essential.
Do not wait until problems surface. Routine fluid analysis gives an early-indicator snapshot of system health. By sampling and testing fluids at regular intervals (as recommended by the press manufacturer or at least quarterly for high-use presses), you monitor for wear metals, moisture, contamination, and fluid breakdown.
When analysis indicates a problem, don't just top off the fluidâreplace it fully. Always use the grade and type of oil specified by the OEM. Label reservoirs and create documentation for all fluid changes.
Overheating is a killer for hydraulic systems. Use infrared thermometers or built-in sensors to monitor operating temperatures during normal press cycles. Record temperature readings and set alert thresholds at safe limits (typically between 110°F to 140°F, unless otherwise stated by equipment maker).
Continuous monitoring with programmable logic controllers (PLCs) or smart controls like the I-PRESS system enables real-time alerts when temperature anomalies are detected. Rapid response can avert thermal breakdown and save seals, hoses, and expensive actuators.
Filtration is your frontline defense. Establish a hard schedule for filter changesâmany suppliers suggest every 1000 operational hours but check your manufacturer's recommendations. Always keep spare filters in inventory and never operate the press without a filter installed.
Select filters with proper micron ratings for the application. Watch for high differential pressure across the filter, which signals clogging. Track these readings in a maintenance log; sudden increases may indicate unusual contamination events that need addressing.
Assign daily visual inspections for hydraulic leaks around hoses, fittings, cylinder seals, valves, and pumps. Leaks not only waste oil but also introduce air, lowering performance and risking cavitation in pumps.
Use absorbent pads or mats under equipment and investigate all signs of fluid build-up on or beneath presses. Tag and address leaks as soon as foundânever accept a "weep is normal" mindset.
Contaminants and moisture often enter hydraulic systems via dirty or worn breathers. Inspect and replace reservoir breathers on a scheduled basis, particularly in humid or dusty environments. Record all maintenance actions for accountability.
Schedule regular reservoir cleaning and fluid draining to remove settled sludge and particles that escape filtration. Reservoirs should never be capped air tightâa good breather is indispensable.
Lockout/tagout is not negotiable. Before servicing any part of the hydraulic system, bleed all pressure, disconnect power sources, and verify a zero-energy state by actuating the press and confirming no residual motion. Open guard doors and work only after confirming complete deactivation.
Provide operator and maintenance staff with up-to-date training in safe hydraulic practices. Display laminated safety checklists at each press.
Adopt tiered schedulesâdaily, weekly, monthly, and annual maintenance routines.
Using digital maintenance management systems or spreadsheets, document every action: what was inspected, what was replaced or adjusted, fluid readings, anomalies found, and repair notes.
Modern hydraulic presses offer integrated diagnostic systems capable of flagging abnormal readings and trending performance data over time. Utilize these to automate condition-based maintenance alerts, further minimizing unexpected failures.
Intelligent controls permit remote monitoring and automated shutdowns in response to critical system issues. Stay ahead of problems by reviewing analytics and acting on early warnings rather than waiting for breakdowns.
Dirt, dust, and debris are common enemies of hydraulic systems. Institute cleanroom practices where possible: keep the press area swept, avoid stacking materials near reservoirs, and mandate "closed fluid" transfer systems when refilling tanks.
Seal off reservoirs when not in active use and regularly wipe down exterior press surfaces to prevent contaminant migration.
A proactive maintenance culture is built on knowledge and shared accountability. Regularly retrain technicians and operators in fluid management protocols, warning signs, and emergency response. Encourage reporting of anomalies without penalty and foster a no-blame approach to solving problems.
Properly maintained hydraulic fluid management systems underpin not only the performance and reliability of your presses but also the safety and profitability of your entire operation. Adopting a disciplined and thorough inspection and maintenance program, leveraging modern diagnostic tools, and instilling a culture of proactivity will ensure your hydraulic presses deliver peak performance year after year.
For companies serious about maximizing uptime and minimizing risk, there is simply no substitute for rigorous, scheduled, and documented fluid management best practices. Start todayâyour presses, your team, and your bottom line will thank you.
Personnel safety is paramount for any presses no mater what type of controls it is equipped with. I-PRESS & Automation controls are the most advanced 4.0 control on the market. We have a family of controls for Servo Hydraulic, Mechanical Stamping and Forge Presses.
Upgrading to I-PRESS Controls is more than a technological leapâit's an investment in safety, productivity, and the future of your manufacturing. Embrace smart automation, secure your workforce, and harness world-class hardware and software platforms. With remote connectivity, rich data, and dedicated online support, you unlock the full potential of modern press operations both today and tomorrow.
Visit our I-PRESS Simulator for hands on demo > https://www.sutherlandpresses.com/i-know?tab=ipress&sec=6a
Want to know more, e-mail: I-PRESS@SutherlandPresses.com or call +1-310-453-6981
No matter what type of press and lubrication systems are a crucial part of keeping your press running smoothly and preventing major damage. Heat build up and the drive system and slide guidance can cause expensive downtime and repairs.
Industrial presses are marvels of engineering, yet they face a silent adversary: friction. Beneath the surface of every productive press operation, moving componentsâflywheels, clutches, bearings, slide guidesâare all subject to relentless mechanical stress. The essential barrier standing between effortless, precise operation and catastrophic failure is effective lubrication.
Unfortunately, many operators and maintenance teams underestimate the importance of well-maintained lubrication systems. The assumption is often that as long as the press operates, the lubrication is "good enough," leading to sporadic inspections, inadequate lubrication intervals, or reliance on manual guessing.
Let's translate this oversight into real-world consequences.
Despite the advancements in press technology and the implementation of sophisticated control systems like the I-PRESS family, the most common cause of costly press failure remains neglect of basic lubrication fundamentals.
Understanding Grease Lube Systems Grease-based lubrication is common in many presses, designed to handle high-load, intermittent use, and environments where oil might leak away. Modern grease systems can be monitored and adjusted via on-press HMIs, and often feature programmable intervals, stroke counters, and distributor blocks for precise delivery.
Best Practices for Inspection and Maintenance
Understanding Recirculating Oil Systems These automatic systems circulate oil continuously or at set intervals, ensuring lubricated surfaces receive a constant, controlled supply. Automatic oil systems are favored in high-speed, continuous operations where heat dissipation and consistent film coverage are critical.
Best Practices for Inspection and Maintenance
Embracing proactive maintenance goes hand-in-hand with adopting available technologies. Systems like I-PRESS and modern HMIs provide critical real-time feedback, historical data logging, performance alerts, and even automatic shutdowns for low lube conditions. Use these tools to:
Neglecting press lubrication doesn't just lead to minor headaches, it can bring your operations to a grinding halt. By respecting the pivotal role of lubrication and making inspection and maintenance of both grease and automatic oil systems a top priority, plants maximize uptime, protect valuable capital assets, and assure safety and quality with every stroke.
Begin your journey by reviewing your press lubrication protocols today, engage your team with updated training, and make full use of real-time monitoring capabilities. Each drop of grease or oil is an investment in your productivity, safety, and bottom line.
For more detailed instructions and tips, consult resources such as Sutherland Press Maintenance Tipsâyour roadmap to a fully optimized press and lubrication system.
Our PMP programs prove to increase press up-time and reduce maintenance. We document all press systems with photos and detailed description of status. A grade of Green-Yellow-Red indicator makes it easy for the end user and management team to know where key issues are that need to be addressed.
No manufacturer can afford the high cost of unexpected downtime. For press operators and decision-makers in metal forming, forging, and heading, downtime wreaks havocâlost productivity, unplanned overtime, delayed shipments, and unhappy customers. Equipment failures strike with no warning, grinding operations to a halt. The culprit? Neglected maintenance, undetected wear, and overlooked safety issues.
In today's competitive marketplace, every minute your press is down means revenue lost that you will never recover. And unplanned breakdowns don't only cost you money, they erode your reputation, disrupt customer relationships, and reduce your capacity to take on new business.
Is this a risk you're willing to take, knowing margins are already thin and stakes are at an all-time high?
When equipment problems aren't addressed in time, what starts as a minor issue can quickly spiral out of control:
Consider the domino effect of a single unplanned outage: the press sits idle, waiting for parts; trained operators are shuffled to other areas, reducing efficiency; promised delivery times slip, and suddenly, your best customer is on the phone demanding answers.
Too many companies believe their in-house teams can stay ahead of it all, only to learn (the hard way) that reactive maintenance is no match for rigorous, data-driven care.
Even world-class operators are vulnerable: According to industry data, unplanned downtime accounts for 23% of all lost production hours in forming and forging plants. How much of your annual revenue could that swallow?
Imagine if every problem on every press was spotted at its earliest stageâbefore it became a crisis. Imagine knowing, with confidence, that each machine would deliver peak performance shift after shift, year after year. That's the power of the Sutherland Presses PMP / Preventative Maintenance Program.
Our PMP is engineered to eliminate uncertainty. It's more than a checklist, it's a comprehensive, proactive solution tailored to your exact equipment. We merge expert diagnostics, real-world experience, and advanced tracking tools to ensure nothing falls through the cracks:
Each press inspection yields a highly detailed report using a visual Red-Yellow-Green (RYG) system:
Having every item backed by clear photographs and technician notes means you're in control with full transparency.
Receive professional inspection reports designed for your operation, including:
Don't just take our word for it, see the evidence in our success stories. Our most notable example: One of our Fortune 100 customers achieved over 107 million strokes in five years with zero unplanned downtime. That's world-class reliability, made possible by strict adherence to Sutherland preventative protocols.
Our PMP features scheduled maintenance built around your production calendar. Never guess about intervals or wonder about overdue checks: You receive automated reminders, prioritized action lists, and direct scheduling with certified technicians.
Catching small issues before they escalate saves thousands on repair bills and weeks of lost operation. Customers consistently comment on the value: one minor hydraulic leak fixed proactively costs a fraction of the major teardown required if left to fail.
Our team follows strict safety protocols on every site visit. All inspections are documented in line with OSHA and industry standardsâreducing your risk of fines, claims, or legal exposure.
We enable your in-house teams through education and hands-on training during each PMP visit. Our Red-Yellow-Green reports double as teaching tools, helping your technicians learn how to spot and address emerging risks every day.
You gain the confidence that comes from knowing every press is monitored with the best tools and practices available. Sutherland stands behind every inspection, giving you direct access to technical experts and a clear, reliable schedule of care.
Looking for proof? Read the news article about our Fortune 100 client who achieved over 107 million press strokes with no unplanned downtime, thanks to unwavering adherence to the Sutherland PMP program. In five years, they never once lost a shiftâmaximizing production, quality, and profitability.
The risks of unplanned downtime are too severe to ignore. With razor-thin margins and customer demands rising, choosing to wait and see is no longer an option. The Sutherland Presses PMP / Preventative Maintenance Program gives you:
Protect your productivity, reputation, and peace of mind. Enroll in Sutherland's PMP.
Want a sample PMP report with photo-supported RYG items? Contact Info@SutherlandPresses.com
Explore the full story of our 107 million stroke success here.
Choose productivity. Choose safety. Choose Sutherland PMP.
(This report contains a summary of features and outcomes for our Preventative Maintenance Program. For a detailed breakdown, schedule a consultation or request a sample report.)
Obviously capital equipment is expensive and the return on investment is very important. The systems and fundamentals mention in the 11 step Maintenance Tip for presses need to be ingrained into operators, set up and maintenance teams.
At Sutherland Presses and 3 generations in the business, we have seen about every type of problem that can be imagined. As the footer of this document states, "A good description of the problem is half the solution".
A great way to think of your press is by system, cause and effect and related components in the chain. This allows companies to diagnose, identify and solved press equipment problems.
If you would like a quote for PMP on your presses, e-mail: service@sutherlandpresses.com
Free downloadable maintenance log templates to track your press maintenance activities.
Download NowNeed assistance? Our expert team is ready to help with your press maintenance needs.
Contact Support*Safety Notice: Safety for operators and staff are the most important parts of press use. The eleven (11) systems mentioned above are all inter-woven into what makes up the press. Failure of any one of the above can cause unsafe working conditions or damage to other parts of the press. It is the employer's responsibility to makes sure presses are in top running and safe condition.
While the following suggestions are based on Sutherland and general presses, your press may be configured differently but the overall suggestions apply to most presses.
