PRESS MAINTENANCE TIPS

Fundamentals & Importance

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).

• Facility provided air to presses and equipment should be clean and dry, which is not always the case.
• A master air supply / lockable air dump valve should be first in-line to provide air to the press.
• Pressure regulators & air pressure monitors on the press should be properly set to factory recommended pressures.
• Maintenance staff should refer to the air system schematic to be sure they are checking all systems.
• No Leak condition throughout the air system should be verified during routine maintenance.
• Air Supply storage tanks should be drained weekly of any condensation or moisture.

Items that could be on your press depending on the type of press:

• Air supply / surge tanks (secure and no leak condition)
• Air supply / surge tanks drains to prevent downstream component contamination
• In-line filters, lubricators, pressure regulators & pressure switches
• For items that have inline mist lubricators, be sure oil level is correct
• Quick connect outlets for connection of air tools
• Dual valve for clutch and brake with muffler to activate CB unit (see #3 CB tips)
• Rotary swivel air inlet joint at CB unit
• Flywheel brake
• Slide locking systems on hydraulic presses
• HOLP / Air over hydraulic overload system, and pump (see #7 HOLP tips)
• Air counterbalance systems (see #2 ACB tips)
• Air-line hoses and connection fittings

Fundamentals & Importance

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 gauge, 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.

• ACB Systems are the most overlooked & improperly used systems on stamping presses.
• Never open ACB cylinders unless all air is drained from the press and apply lock out / tag out rules.
• Understand the difference between static load (slide not moving) and dynamic load (slide moving) to set proper ACB pressure based on upper tool weight and press speed.
• If your press is equipped with a main motor Amp gauge , this is a great tool to set proper ACB pressure. Adjust ACB to main motor amp gauge shows minimal movement or fluctuation.
• Properly set ACB pressure allows good clearance for lubrication circulation to all bearings and bushings in the drive.
• Caution: too low pressure will cause a jackhammer effect on all bearings, bushings slide adjustment mechanisms, hydraulic overload and drive gear backlash.
• Maintenance should be sure to drain ACB air supply tanks weekly to remove any moisture.
• Inspect lubrication to ACB cylinders to make sure seals and packings are properly lubricated.
• Inspect ACB rods that connect cylinders to slide and make sure no scoring marks are present. If visual scoring marks are present, this would indicate the seals and packing may be leaking of damaged

Fundamentals & Importance

Section 1: DRY Air Clutch & Brake Systems

DRY Air Clutch & Brake Systems are a crucial part of mechanical presses. If any part of the air system to the CB System is leaking or not functioning properly, it should be reported to the 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 upkeep—even for a week—can 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 neglect—your 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 time—mid-run, with a rush order and an impatient customer waiting.

SOLUTION:

Prevent disaster with a comprehensive dry clutch/brake maintenance regime:

• Weekly: inspect the full die area before activation. All tools and personnel must be clear; point-of-operation guards firmly in place.
• In inch mode: check for smooth, responsive operation; in single stroke, ensure the slide always stops near Top Dead Center; test the emergency stop in continuous for instant engagement.
• Every week: drain all air supply tanks. Moisture is the enemy.
• Clean out exhaust mufflers on electronically controlled clutch valves, preventing unexpected blockages or response delays.
• Monthly: examine flywheel brake travel, replace thin or glazed pads, and confirm all stopping functions meet manufacturer specs.
• Always maintain correct air pressure per your press manual, too low risks clutch hammering and rapid wear, while too high strains the main motor and increases amp draw.
• Maintain a spotless work area to keep dust from contaminating linings and linkage and adhere strictly to a scheduled replacement of wear parts.

The cost of disciplined routine checks shrinks in comparison to lost production, tooling wear, or—worst of all—operator injury. With vigilant dry clutch and brake unit upkeep, presses stay safe, responsive, and reliable, maximizing uptime and minimizing life-cycle costs.

Section 2: WET Clutch and Brake Systems

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 inspections—issues 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 hesitates—then 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.

SOLUTION:

Guard against these failures with a robust wet clutch/brake maintenance protocol:

• Perform frequent oil checks—monitor both level and clarity. Top up oil as needed with the manufacturer-specified fluid and never mix types and be sure to not over fill the unit.
• Replace oil on a regular schedule, and analyze samples if production is intense or contamination is suspected.
• Inspect for leaks in all hydraulic and lubricated circuits; correct any issues before they compromise motor performance or pressure stability.
• Clean all components that interact directly with oil, such as sumps, reservoirs, and lines, to prevent grit or sludge from circulating.
• Confirm that pressure settings are corrected for both static and dynamic operation; excessive pressure overheats fluids, while insufficient pressure causes hammering and wear.
• Regularly check pad and plate thickness, replace these wear points before they jeopardize system responsiveness or lead to warping.
• Maintain a proactive spare parts inventory for filtering elements, seals, and linings so that unplanned repairs never stretch into days or weeks.

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.

Summary

Dry and wet clutch/brake units are linchpins of stamping press safety and performance—and 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.

Fundamentals & Importance

Problem:

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.

Agitate:

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 overloads—press 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.

Solution:

Protect your assets with a thorough understanding and vigilant maintenance of every connection in your press drive system. Here's how:

1. Master Your Mechanical Connection Points:

• Motor/Flywheel Coupling: Ensure proper alignment and torque, choose couplings that match operational demands, and check for excessive wear.
• Flywheel/Clutch: Keep your clutch mechanisms responsive and energy transfer efficiently to support smooth conversions from rotational to linear power.
• Clutch/Crankshaft: Regularly inspect clutch engagement to prevent backlash or slack, which can magnify the effect of reverse tonnage.
• Crankshaft/Ram: Monitor connecting rods for fatigue, so the ram maintains consistent force and travel under all conditions.

2. Set ACB (Air Counterbalance) Pressures Precisely:

• Calibrate static ACB pressure when the ram is stationary to perfectly balance the upper die and slide, reducing unnecessary wear.
• Adjust dynamic ACB settings for higher stroke speeds (SPM), as faster cycles need extra support to counter inertia and prevent hammering at each turnaround.
• Regularly monitor ACB valves and cylinders for leaks, contamination, or sluggish response to avoid gradual loss in counterbalance.

3. Maintain Correct HOLP (Hydraulic Overload Protection) Settings:

• Set HOLP to safeguard against accidental overloads. Test trip functions and verify pressure integrity before every production run.
• Recognize that every die change and material type may require a new setting of your tonnage monitor, never assume one universal setting is safe.

4. Defend Against Snap-Thru Tonnage:

• For blanking work, understand your press's upper limit for reverse tonnage. A good rule of thumb, reverse tonnage should be less than 10% of press capacity. 10-15% caution zone and 20%+ is in the red zone.
• Use die cushioning, shock-absorbing dampers, or dedicated blanking presses to reduce impact forces. Routinely inspect all drive connections for signs of impact fatigue.
• Incorporate electronic tonnage monitoring to catch excess loads in real-time, initiating corrective action before damage sets in.

5. Train and Empower Your Team:

• Provide ongoing training for operators and maintenance techs on the intricacies of connection points, pressure settings, and tonnage effects.
• Give them the tools to spot and fix issues quickly—not just patch problems but address their root causes.

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.

Fundamentals & Importance

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.

Problem: Hidden Electrical Failures Threaten Press Safety, Uptime, and Productivity

Your press is a workhorse—every 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.

Agitate: Overlooking Electrical Maintenance Carries Real Consequences

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 issue—or 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.

Solution: Proper Inspection, Testing, and Strict Controls Secure Press Performance

Protect your press, your people, and your productivity: implement a structured, methodical approach to press electrical maintenance and enclosure inspection.

Establish Weekly Functional Testing Protocols

• Assign qualified, trained personnel to test every press control and function—start, stop, emergency stops, limit switches, interlocks, and safety circuitry and point of operation guards.
• Log every anomaly or lag in activation. Initiate immediate investigation and repair for anything that deviates from normal operation.

Enclosure Inspection and Cleaning

• Open electrical enclosures only when the press is shut down and fully de-energized, lockout/tagout in place.
• Check for dust, moisture, corrosion, or evidence of overheating (such as discoloration or burnt odor).
• Verify tightness of all terminal screws and connector blocks. Gently remove debris with approved brushes or vacuum; never use compressed air, which can drive particles deeper.

Cabling and Component Check

• Inspect all wiring and harnesses for wear, abrasion, or signs of arcing.
• Confirm that all cable runs remain firmly anchored, free of pinching or excessive bending.
• Assess relays, contactors, and fuses for signs of wear or pitting.

Environmental Control

• Ensure all gaskets and seals on enclosures prevent moisture or dust ingress.
• Maintain ambient temperatures within manufacturer recommendations, using filters or air conditioning for sensitive units.

Strict Policy: Access and Modifications

• Only trained, authorized personnel are allowed to access control panels or electrical enclosures.
• Never modify, bypass, or rewire press controls or safety circuits without written approval from the press builder. Unauthorized adjustments void warranties, risk press integrity, and threaten operator safety.

Documentation and Reporting

• Require detailed inspection and test logs, documenting all findings and corrective actions.
• Report and address all anomalies; escalate persistent issues to authorized service providers or the press manufacturer for guidance.

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 to rigorous, scheduled inspection, testing, and strict control of all electrical maintenance activities.

Unseen electrical issues are ticking time bombs—but 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.

Upgrade & Retrofit Option

Why Press Users Should Upgrade to I-PRESS Controls: A Compelling Case

• Move Into the Future With I-PRESS Controls
  • Unlock your press room with cutting-edge control technology engineered for the demands of modern manufacturing.
  • Embrace smart machine innovation that positions your business for Industry 4.0 readiness—seamlessly integrating presses into the digital era.
• Realize The Power of Smart Machines
  • Transform your presses from mechanical workhorses to intelligent, connected assets with I-PRESS Controls.
  • Built-in analytics and adaptive control features optimize press performance and enable real-time decision-making.
• Built For Industry 4.0
  • I-PRESS Controls are architected for compatibility with leading-edge industrial IoT frameworks.
  • Elevate your operation through interoperability with a wide range of industrial systems, making your presses part of the bigger smart factory vision.
• Remote Connections for Modern Manufacturing
  • Enable remote monitoring and control from anywhere, at any time.
  • Plant managers, maintenance teams, and engineers gain mobile, flexible access—minimizing downtime and allowing support without travel.
• Data Collection: Actionable Insights at Your Fingertips
  • Capture critical production and process data automatically.
  • Metrics, trends, and diagnostics are centralized, enabling artificial intelligence and predictive maintenance for improved uptime and quality.
• Unmatched Online Service Support
  • I-PRESS Controls come with robust online support tools. Fast issue resolution is just a call or click away.
  • Reduce the need for on-site service visits; technical experts can diagnose, troubleshoot, and update your controls remotely.
• World-Class Hardware and Software
  • I-PRESS is built upon the best platforms: Rockwell Automation (Allen Bradley), Siemens, and Omron.
  • Enjoy the reliability, scalability, and global support these premiere brands are known for.
  • Seamless software and firmware updates ensure your system stays current with minimal disruption.
• Scalable Solutions for Every Operation
  • Easily upgrade a single press or roll I-PRESS Controls out across your entire plant—future growth is streamlined.
  • Modular architecture means you pay for the capabilities you need now and add more as your requirements evolve.
• Deep Customization for Unique Processes
  • I-PRESS software adapts to your individual press application and production workflows—no more one-size-fits-all limitations.
  • Custom screen designs, user rights management, and process-specific logic are standard.
• Return On Investment: Why Wait
  • Experience reduced downtime, better part quality, and faster setups.
  • Online diagnostics and remote support lower service costs and reduce the need for expensive on-site visits.
  • Futureproof architecture protects your investment as standards and requirements evolve.
• Upgrade With Confidence
  • Transition smoothly knowing I-PRESS Controls integrate seamlessly with legacy sensors and actuators, minimizing installation headaches.
  • Comprehensive migration guides and support ensure your press line is back up and running quickly.
• Join Leading Pressrooms Worldwide
  • Leading global manufacturers have adopted I-PRESS Controls for reasonable reliability, advanced features, and ongoing innovation.

Making the Shift

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

The Importance of Press Slide Guidance, Gibs, and the Relationship of Parallelism and Die Life

Problem: The Hidden Cost of Neglecting Precision in Press Slide Guidance

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 — all essential for prolonged die life and consistent product output.

Agitate: When Small Errors Become Expensive Failures

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:

• Concentrated die shoe loads, causing uneven wear to die components.
• The incremental opening of punch-to-die clearances, increasing die breakage risk.
• Accelerated wear on die guide pins, bushings, and critical surfaces.
• Higher shear forces and shock loads, shortening overall die life and potentially damaging the press.

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 — most damaging of all — a loss of customer trust.

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.

Solution: Precision Slide Guidance, Optimally Set Gibs, and Proactive Parallelism Management

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.

1. Precision Slide Guidance Design

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:

• Specifying press designs with robust, adjustable gib systems appropriate for the load and stroke profile.
• Selecting wear materials and lubrication systems tailored to operating conditions.
• Committing to periodic gib adjustment protocols—during scheduled maintenance.

2. Optimal Gib Setting and Maintenance

Gibs must be set with precise clearance—tight 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:

• Use manufacturers' specifications and certified indicators for gib adjustment.
• Log gib inspection and adjustment as part of scheduled preventive maintenance (PMP).
• Replace worn gib liners or surfaces proactively—before they reach critical wear limits.

3. Monitoring and Maintaining Parallelism

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:

• Regularly measuring slide-to-bolster parallelism using precision tools like dial indicators or laser alignment systems.
• Making necessary slide or ram adjustments to correct any detected deviation.
• Documenting all checks and corrections within the core documentation framework to support continuous improvement and accountability.

4. Comprehensive Training and Culture

Technical systems only perform as well as the people who maintain and operate them. Manufacturers must:

• Invest in regular training for operators, setup staff, and maintenance teams on the importance of gibs, slide guidance, and parallelism.
• Foster a culture where small deviations are recognized as early warnings—triggers for proactive maintenance, not as mere nuisances.
• Empower teams to submit quality control issues and respond to early feedback before die and press damage become irreversible.

5. Leveraging Digital Tools for Documentation and Accountability

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.

Conclusion

The essence of high-performance stamping and forming is not just in technology, but in the disciplined application of age-old principles—precision 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 runs–protecting 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.

Fundamentals & Importance

Are You Sacrificing Your Press to Overloads? How Hydraulic Overload Protection (HOLP) Keeps Your Operation Profitable and Safe

Problem: The Silent Threat Lurking in Your Pressroom

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 setup—can 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 down—a 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.

Agitate: When One Missed Step Turns into a Costly Breakdown

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:

• Overfilled HOLP tanks leaving no space for displaced oil, causing the system to malfunction or create pressure spikes that damage hydraulic components
• Operators and maintenance teams adjusting pressure settings beyond factory recommendations, thinking a higher threshold offers more protection—when it brings your press closer to catastrophic failure
• Neglecting simple weekly function checks, so the day a stuck die stops production, your HOLP system sits dormant or worse, fails to trigger
• Underestimating the forces of reverse tonnage from blanking or piercing operations—allowing reversed forces to batter your press with every cycle

Solution: Reliable Protection Through Smart Setup, Monitoring, and Maintenance

The good news is safeguarding your pressroom isn't about complicated routines or expensive upgrades—it's about consistent adherence to a few proven best practices:

1. Understand the True Purpose of HOLP:

Hydraulic Overload Protection keeps your press (and profits) safe by instantly releasing pressure when forces exceed 110 percent of capacity—freeing stuck dies, stopping the press drive, and preventing catastrophic mechanical failure before it starts.

2. Never Overfill the HOLP Tank:

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 go—leading to blown seals and system failure exactly when you can least afford it.

3. Maintain Factory Pressure Settings:

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.

4. Test Weekly, Not Weakly:

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.

5. Address Air Counterbalance (ACB) and Reverse Tonnage:

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.

6. Seek Out Innovative Solutions as Needed:

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.

Conclusion: Don't Let Routine Lapses Threaten Your Most Valuable Asset

A hydraulic overload event will happen—it'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 luck—it's the result of understanding, prevention, and disciplined maintenance. Keep your HOLP system healthy, and your press will keep your business strong.

Fundamentals & Importance

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.

Best Practices for Inspection and Maintenance of Hydraulic Press Fluid Management Systems: Problem-Agitate-Solution

Problem

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 overnight—rather, 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.

Agitate

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 surfaces—a 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. Hydraulic press fluid failures rarely give early, obvious warning signs. Subtle changes—slower cycle times, increased noise, slightly elevated temperatures—are the blips before the storm. When these are missed due to poor inspection or sloppy maintenance, the results are disastrous.

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.

Solution

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 optional—it is essential.

1. Implement Regular Hydraulic Fluid Analysis and Replacement

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 fluid—replace it fully. Always use the grade and type of oil specified by the OEM. Label reservoirs and create documentation for all fluid changes.

2. Monitor System Temperatures

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.

3. Maintain Proper Filtration

Filtration is your frontline defense. Establish a hard schedule for filter changes—many 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.

4. Inspect for Internal and External Leaks

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 found—never accept a "weep is normal" mindset.

5. Check System Breathers and Reservoirs

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 tight—a good breather is indispensable.

6. Prioritize Safety in All Maintenance Procedures

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.

7. Establish and Document Preventive Maintenance Schedules

Adopt tiered schedules—daily, weekly, monthly, and annual maintenance routines.

• Daily: Visual checks for leaks, odd noises, temperature excursions.
• Weekly: Filter and breather inspections, hose integrity checks, fluid level readings.
• Monthly: Fluid sampling and analysis, detailed system inspection, pressure calibration if necessary.
• Annually: Comprehensive system flush, replacement of wear components, review of previous year's maintenance logs for trend analysis.

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.

8. Leverage Technology for Proactive Maintenance

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.

9. Keep the Work Environment Clean and Organized

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.

10. Train and Empower Your Team

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.

Conclusion

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 today—your presses, your team, and your bottom line will thank you.

Fundamentals & Importance

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.

Why Press Users Should Upgrade to I-PRESS Controls: Unmatched Advantages for Modern Press Operations

• Unrivaled Smart Machine Integration
  • I-PRESS Controls transform traditional presses into intelligent, responsive Smart Machines.
  • Real-time adaptive control ensures optimal performance and predictive maintenance.
  • Intelligent feedback seamlessly improves uptime and productivity.
• Safety at the Forefront: Cat 3 & PL-D
  • Achieve the highest safety compliance with Category 3 and Performance Level D certifications.
  • Built-in safety circuitry reduces risks, protecting operators and equipment.
  • Enhanced diagnostics enable fast response to any safety event, ensuring full compliance with workplace regulations.
• Fully Ready for Industry 4.0
  • Effortlessly connect I-PRESS Controls to your smart factory environment.
  • Unlock advanced automation, analytics, and artificial intelligence features.
  • Future-proof your investments with a scalable and upgradable Industry 4.0 platform.
• Seamless Remote Connections
  • Monitor and control presses from anywhere in the world.
  • Instantly respond to system alerts and performance fluctuations, reducing downtime.
  • Remote troubleshooting and rapid updates keep presses at peak performance.
• Comprehensive Data Collection
  • Capture every aspect of your production process for complete traceability.
  • Leverage detailed data to optimize throughput and slashing inefficiencies.
  • Enable predictive maintenance and long-term insights with precise machine analytics.
• 24/7 Online Service Support
  • Get expert assistance at any hour for fast issue resolution.
  • Minimize downtime with remote diagnostics, configuration, and support.
  • Global coverage ensures critical applications are always supported.
• Built on Industry-Leading Platforms
  • I-PRESS integrates top-tier hardware and software: Rockwell Automation AB, Siemens, and Omron.
  • Robust, reliable components for exceptional long-term performance.
  • Native compatibility with major PLCs and automation systems streamlines integration.
• Flexible Scalability for Any Operation
  • Suitable for single presses to large, multi-press lines.
  • Modular design allows for future expansion or updates without replacing major components.
  • Effortlessly adapt as your production needs grow or change.
• Unmatched Customization Options
  • Configure controls specifically for your process, materials, and products.
  • Open architecture enables bespoke solutions from the smallest tweak to complete process redesign.
  • Tailor dashboards, reports, and machine behaviors for unique manufacturing requirements.
• Superior User Experience
  • Intuitive user interfaces enable operators to access advanced features without steep learning curves.
  • Fast setup and commissioning get presses up and running quickly.
  • Sophisticated alarms, maintenance reminders, and documentation keep everyone informed and efficient.
• Continuous Innovation and Upgrade Path
  • I-PRESS is regularly updated to incorporate new security, performance, and usability features.
  • Maintain your competitive edge with future-ready software upgrades.
  • Stay ahead of regulatory, technological, and business trends with proactive updates.

In summary:

Upgrading to I-PRESS Controls is more than a technological leap—it'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.

Fundamentals & Importance

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.

The Crucial Role of Press Lubrication Systems: Understanding, Inspecting, and Maintaining Grease and Automatic Recirculating Oil Systems (Problem-Agitate-Solution)

The Problem: Overlooked Lubrication – The Hidden Threat Lurking Inside Press Machines

Industrial presses are marvels of engineering, yet they face a silent adversary: friction. Beneath the surface of every productive press operation, moving components—flywheels, clutches, bearings, slide guides—are 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.

The Agitation: What Happens When Lubrication Goes Wrong?

Let's translate this oversight into real-world consequences.

• Escalating Repair Bills: When lubrication becomes insufficient, friction increases, rapidly accelerating wear on critical press parts. Small issues—like minor scoring of a slide or a sticking clutch—quickly snowball into major breakdowns, requiring expensive replacements and extended downtime.
• Unscheduled Downtime: Unrecognized lubrication failures can bring entire production lines to a halt. A seized bearing or a sheared crankshaft is not just a mechanical issue, it means missed deadlines, lost profits, and dissatisfied customers.
• Inconsistent Quality: Poor lubrication leads to uneven wear, resulting in misalignment and precision errors. That means more rework, rejected parts, and tarnished reputations.
• Safety Risks: Overheated or worn parts are safety hazards to operators and the facility. Failed lubrication increases the risk of catastrophic mechanical failure—potentially causing injury.
• Hidden Maintenance Costs: When lubrication systems malfunction—or are ignored—maintenance becomes reactive, not proactive. Emergency repairs are always costlier than strategic upkeep.

The Solution: Embrace Proactive Inspection and Precision Maintenance of Press Lubrication Systems

Group 1: Grease Lubrication Systems – Inspection and Maintenance

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

• Regular Interval Inspections: Align lubrication intervals with press stroke counts, not just time. For example, if your controller is set to lubricate every 3,000 strokes, verify this rate is adequate by monitoring wear and grease buildup. Excess grease is wasteful, too little leads to rapid part degradation.
• Check Grease Delivery Points: Visually inspect all grease lines, fitting points, and collection trays. Look for signs of dry spots, excessive leakage, or contamination.
• Distributor Block Functionality: Use system diagnostics or manual cycling to ensure each distributor block pulse is matched by a visible movement of grease and that no stroke is being missed.
• Monitor Grease Quality: Replace the grease if contamination (dust, debris, metal shavings) is detected. A contaminated lubricant can damage components more quickly than no lubrication at all.
• Prime as Needed: If air enters the system (often after reloading or maintenance), use the prime function to restore effective flow before resuming full production.
• Keep Detailed Records: Use digital tools or logbooks to track which jobs, intervals, or environmental conditions necessitate changes to lubrication parameters.
• Environment Management: Maintain a dust-free (or as clean as possible) area around the press to prevent foreign matter from entering grease points. Adopting cleanroom practices, if feasible, delivers tangible long-term benefits.

Group 2: Automatic Recirculating Oil Systems – 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

• Monitor Oil Levels and Pressure: Regularly check reservoir levels and ensure the oil pump maintains correct pressure. Low levels could indicate leaks or excessive consumption.
• Check for Leaks: Inspect fittings, lines, and joints for seepage, which can lower system pressure and reduce lube effectiveness.
• Oil Quality is Paramount: Replace oil at manufacturer-recommended intervals, or sooner if color, viscosity, or clarity changes. Oil analysis (checking for metal particulates, water, or oxidation) is a smart predictive maintenance practice.
• Verify Flow to All Points: Modern systems offer feedback via flow meters or electronic indicators. Confirm each lubrication point (bearings, slides, gears) receives proper flow; even minor blockages can cause local overheating.
• Clean or Replace Filters: Filters trap debris, ensuring only clean oil reaches moving parts. Clogged filters reduce flow and pressure—a common but easily avoidable failure point.
• Calibrate Delivery Settings: Use built-in system controls to match delivery rates to job demands—excess oil wastes resources and can contaminate press components, while insufficient oil increases wear.
• Environment Management: As with grease systems, keep the work area clean. Oil leaks attract dust/dirt, which can then enter the system or abrade components.

The Future: Leveraging Technology and Best Practices

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:

• Schedule inspections based on usage data, not just time-based calendars.
• Adjust lubrication settings on-the-fly based on actual job requirements and observed conditions.
• Detect anomalies before they become problems.

Takeaway

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 Tips—your roadmap to a fully optimized press and lubrication system.

Fundamentals & Importance

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.

Why You Must Enroll in Sutherland Presses PMP / Preventative Maintenance Programs

Problem: Unexpected Downtime is a Productivity Killer

No manufacturer can afford the high cost of unexpected downtime. For press operators and decision-makers in metal forming, forging, and heading, downtime wreaks havoc—lost 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?

Agitate: The Real Cost of Neglect

When equipment problems aren't addressed in time, what starts as a minor issue can quickly spiral out of control:

• A worn bearing is ignored—it shreds under heavy load, damaging shafts and gearing, leading to a $75,000+ repair bill plus weeks of lost production.
• Electrical contacts heat up and degrade—the resulting failure damages your control panel, requiring expensive rush orders and system reprogramming.
• Safety interlocks aren't checked. A critical incident occurs, exposing your plant to regulatory fines and employee injury.

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.

Solution: The Sutherland Presses PMP / Preventative Maintenance Program

Imagine if every problem on every press was spotted at its earliest stage—before 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.

What Sets PMP Apart?

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:

1. Actionable Red-Yellow-Green Reports—With Photos

   Each press inspection yields a highly detailed report using a visual Red-Yellow-Green (RYG) system:

   • Red Items (Immediate Action): These findings demand your full attention now. Items like critical cracks, major leaks, or outright component failure are highlighted in red—with clear photos and location tags—so you know exactly what must be corrected to stay out of crisis mode.
   • Yellow Items (Caution / Monitor): Early warning signs of trouble, such as minor hydraulic seepage, abnormal wear, or rising noise levels, are tracked in yellow. Paired with checklists and photos, you'll see what needs planning before it becomes a larger risk.
   • Green Items (Good): Confirmed areas of healthy operation are flagged green. Your team has peace of mind, knowing these are fully functional, giving you the freedom to focus on resources where they're most needed.

   Having every item backed by clear photographs and technician notes means you're in control with full transparency.

2. Tailored Documentation for Compliance and Analysis

   Receive professional inspection reports designed for your operation, including:

   • Technician's diagnostics photos and remarks
   • Maintenance recommendations prioritized by urgency
   • A cumulative history, so you can monitor trends and demonstrate compliance to auditors and insurers
3. Proven, Measurable Results

   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.

4. Scheduled, Systematic Inspections

   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.

5. Reduced Total Cost of Ownership

   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.

6. Enhanced Safety and Regulatory Compliance

   Our team follows strict safety protocols on every site visit. All inspections are documented in line with OSHA and industry standards—reducing your risk of fines, claims, or legal exposure.

7. Continuous Improvement Culture

   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.

8. Uptime, Accountability, Peace of Mind

   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.

Real-Life Impact—107 Million Strokes, Zero Downtime

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 shift—maximizing production, quality, and profitability.

Summary: Invest in Reliability, Outperform the Competition

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:

• A data-driven, actionable roadmap for every press in your plant
• Immediate visibility through illustrated Red-Yellow-Green reports
• Lower lifetime costs due to early intervention
• Regulatory compliance and maximum equipment life
• The competitive advantage of world-class reliability

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.)

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Obviously, capital equipment is expensive, and the return on investment is significant. The systems and fundamentals mentioned 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