Revamping Industrial Efficiency: A Case Study on Modernizing Forging Presses

The Problem

A leader in the global aerospace and defense industry was experiencing significant operational inefficiencies. The core of these issues was in the malfunctioning of their key assets – a 2500 Ton Mechanical Bliss Press and a 300 Ton Hydraulic Bliss Press.

The primary challenge was the overheating of the existing flywheel bearings in the 2500 Ton Press due to flawed design. The system’s performance was compromised, leading to operational inefficiencies and increased risk of component failure. Furthermore, the electrical controls, pneumatics, and safety measures were outdated, hindering the overall productivity of the forging line.

The Solution

Addressing these issues, the Ajax/CECO/Erie Press team took up the challenge to revamp and revitalize these integral machines.

Firstly, a complete rebuild of the 2500 Ton Mechanical Bliss Press was carried out with a focus on rectifying the flywheel bearings’ overheating problem. The existing design was replaced with a more effective one, ensuring the normal functioning of the bearings.

Secondly, the 300 Ton Hydraulic Bliss Press also underwent a comprehensive rebuild. Both machines were then integrated into the press cell, comprising conveyors, robot arms, and a furnace.

All new electrical controls were installed, taking into consideration the latest safety and current updates. A more sophisticated pneumatic system was implemented, and numerous thermocouples were added for continuous monitoring of the bearing temperatures during use.

The Outcome

Although the project took longer than initially anticipated, the actual downtime onsite stretched to slightly over a year, and the combined time for design and on-site work approached two years. The results, however, were highly beneficial for the customer.

The refurbished presses, with their upgraded components, improved the productivity and efficiency of the forging line. The new design for flywheel bearings in the 2500 Ton Press eliminated the overheating issue, extending the life of the equipment and reducing the risk of sudden breakdowns.

Furthermore, the incorporation of advanced electrical controls, pneumatics, and thermocouples helped streamline operations, ensure safety, and enable real-time monitoring, thereby improving overall operational efficiency.

The Ajax/CECO/Erie Press Advantage

The success of this project underscores the unique advantage offered by Ajax/CECO/Erie Press. Despite the challenges posed by the project’s length and technical complexity, our team delivered a solution that significantly improved their operational capabilities.

The total cost for the rebuild and integration of both machines, at approximately 4 million dollars, demonstrated our commitment to providing cost-effective solutions without compromising on quality or performance.

Ajax/CECO/Erie Press, with its dedication to high standards, innovative thinking, and customer satisfaction, stands at the forefront of providing efficient, reliable, and state-of-the-art solutions for the most challenging industrial problems


Contact us for more information about our rebuild process.