Success Story: Hydraulic Revamping of a 400-Ton Press with Daikin Hybrid Technology

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Hydraulic Revamping of a 400-Ton Press with Daikin Hybrid Technology

Duplomatic MS and Mekoil Srl carried out the complete hydraulic and control system revamping of a 400-ton hydraulic press, replacing a traditional proportional pump solution with an architecture based on Daikin SUT Hybrid Servo Pumps.

The objective of the project was to increase productivity, reduce energy consumption and noise levels, improve cycle control, and make the machine fully compatible with Industry 4.0 requirements.

 

Previous Configuration

The press was equipped with a 45 kW three-phase electric motor coupled to a 360 L/min variable displacement pump with proportional electric flow control.

Pressure control was managed by proportional cartridge valves, while an air-to-oil heat exchanger controlled by a thermostat was required to dissipate the heat generated by the hydraulic system.

This configuration exhibited the typical limitations of conventional hydraulic systems: a continuously running motor, high-pressure energy losses, excessive noise and heat generation, and overall efficiency no longer suitable for modern production requirements.

 

New Installed Solution

The existing hydraulic power unit was replaced with two Daikin SUT00D20025 Hybrid Servo Pump units rated at 22 kW each, dedicated to the main cylinder. Each unit provides a theoretical maximum flow rate of up to 200 L/min and a maximum operating pressure of 250 bar.

The new architecture therefore delivers a combined theoretical flow rate of up to 400 L/min during rapid approach and return phases, representing a significant increase compared to the previous system.

A third Daikin SUT00D6021 Hybrid Servo Pump unit was installed to control the blank holder circuit, providing a maximum flow rate of up to 60 L/min and a maximum operating pressure of 210 bar.

Separating the blank holder circuit from the main hydraulic circuit allows more stable and independent force regulation throughout the sheet forming process.

 

HP/LP Operating Logic

The dual-pump Daikin SUT units operate under two different conditions.

During rapid approach and return, where high flow is required but pressure demand is low, both the HP and LP pumps operate simultaneously.

During the forming phase, when force demand increases, the system automatically switches to high-pressure mode using only the HP pump, preventing motor overload.

The switching function can be managed automatically by the SUT controller or directly by the machine PLC.

Pressure and flow are controlled through 0–10 V analog signals, allowing the press behavior to be optimized for every stage of the production cycle.

 

Hydraulic Manifold and Safety

Mekoil, together with the Duplomatic engineering team, completely redesigned the hydraulic manifold by eliminating the main proportional valve control architecture and introducing a new generation of on/off valves.

Pressure and flow regulation are no longer performed by proportional valves but directly through servo pump modulation.

This approach reduces pressure losses, simplifies the hydraulic circuit, and improves overall system reliability.

Valve monitoring systems were also integrated to increase operator safety and continuously monitor the status of critical hydraulic components during machine operation.

 

Results Achieved

The revamping significantly increased both press speed and productivity thanks to the higher available flow rate during rapid movements and the faster dynamic response of the hybrid servo pumps.

With essentially the same installed power, measured energy savings reached approximately 70%.

This improvement is achieved because the system generates hydraulic flow and pressure only when required by the production cycle, eliminating the continuous energy losses typical of conventional hydraulic systems.

The lower energy dissipation also dramatically reduced oil temperature, making the previously installed air-to-oil heat exchanger no longer necessary.

In addition, the press now operates much more quietly, providing a significantly improved working environment.

 

Control, Precision and Industry 4.0

The project also included a complete hardware and software upgrade of the machine, featuring a new operator interface and direct integration with the company's manufacturing management system.

The upgraded control system enables real-time monitoring of production cycle parameters, machine status, and daily energy consumption.

This provides full transparency of production costs while allowing continuous analysis of the machine's actual operating efficiency.

The improved control of both the main cylinder and the blank holder has also enhanced forming quality by increasing process repeatability and stability.

 

Conclusion

The revamping transformed a traditional hydraulic press—characterized by high energy consumption, excessive noise, and limited efficiency—into a faster, quieter, more precise, and fully connected production machine.

The implementation of Daikin SUT Hybrid Servo Pumps, the complete redesign of the hydraulic manifold, and the software integration made it possible to retain the existing mechanical structure while substantially improving performance, safety, energy efficiency, and process control.

 

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