Downtime. Inconsistent performance. Outdated controls. Every manufacturer eventually faces the same reality: even the best press needs new life. That’s where Macrodyne comes in.
We don’t offer cookie-cutter fixes. We collaborate. We start by understanding how your press fits into your operation. We learn what’s working, what’s not, and what you want to achieve. Then we engineer a retrofit or upgrade that brings your equipment in line with today’s production demands: faster cycles, smarter control, and safer, more efficient performance.
Every press and every retrofit is unique. That’s why our engineers begin with a full system assessment to determine exactly what needs to be modernized for safety, speed and precision. Whether you’re running a Macrodyne press or another manufacturer’s, our retrofit solutions are engineered to deliver like-new performance, long-term reliability and measurable production gains.
With Macrodyne’s high-force hydraulic presses, you can manufacture critical aircraft, defense, and space components with unmatched accuracy and repeatability. From fuselage panels and jet engine casings to landing gear and spacecraft structures, our advanced forming technologies ensure every part is built to perform.
We replace outdated hydraulic components with modern, high-efficiency systems designed for tighter control, cleaner operation, and faster response. Typical upgrades include: new manifolds, proportional valves, cylinders, pumps and plumbing for precise pressure and speed regulation.
Bring your press in line with today’s digital manufacturing standards. Upgrades can include: PLC and HMI replacements, new control panels, servo motion systems, and data acquisition for real-time process monitoring and analytics.
From part handling to tool changeovers, we design automation that fits seamlessly into your process. Capabilities: robotic loading/unloading, transfer systems, safety guarding, light curtains, and integration with existing plant systems.
Modernize your press to meet or exceed today’s global safety standards. Solutions include: upgraded guarding, interlocks, emergency stops, dual-hand controls, and redundant Category 4 safety circuits.
We engineer every retrofit for measurable improvement — faster cycles, greater repeatability, and reduced maintenance. Examples: optimized motion profiles, energy-saving drives, and process monitoring for predictive maintenance and quality assurance.
Many plants are running presses that were built decades ago by manufacturers that have changed ownership, stopped producing certain models, or no longer provide the level of support required for modern production.
Macrodyne provides inspection, repair, rebuild, modernization, and upgrade services for hydraulic and servo hydraulic presses from all major press manufacturers. Whether your press was built by Macrodyne or another OEM, our team can assess the machine, identify practical upgrade paths, and help extend its working life. From aging hydraulic systems and outdated controls to worn cylinders, frame concerns, safety compliance issues, and automation integration, we help manufacturers determine whether a rebuild makes sense before investing in new equipment.
We get a lot of questions about how our retrofit process works. Here are some of the most common…and our straight answers.
If we’re doing both hydraulics and electrics, a retrofit usually takes about six months from start to finish. That includes the on-site assessment, design, build, installation and commissioning phases.
Most are done on-site. Our team travels to your facility, takes all the data and measurements, and brings that back to Macrodyne for design and build. Once the components are ready, we ship them to your plant and handle the entire installation.
We move quickly once a press is shut down, removing the old systems, installing the new ones, and getting production back online. Most downtime is around six weeks, depending on the project. When a faster turnaround is needed, we help coordinate multiple shifts or extended hours to keep things on track.
Every retrofit is designed, built and managed entirely by Macrodyne. Our technicians handle the rigging, installation, and start-up. Customers don’t need to coordinate multiple vendors. Other than sending a purchase order and turning the power back on when we’re finished, we take care of everything else.
Yes. Macrodyne provides inspection, repair, rebuild, and upgrade services for presses from all major manufacturers, not only Macrodyne-built systems.
Yes. Many rebuild projects involve older presses that are still structurally useful but need updated hydraulics, controls, safety systems, cylinders, or automation.
It depends on the press condition, frame integrity, production requirements, safety needs, and the cost of downtime. Macrodyne can inspect the press and help determine whether rebuilding, upgrading, or replacing the machine is the better path.
Yes. Macrodyne can modernize controls and integrate the press with automation, material handling, die handling, robotics, and other production equipment.
Yes. Macrodyne offers inspection and consulting services to help manufacturers evaluate used presses before buying, relocating, or integrating them into production.
Over the years, we’ve helped manufacturers across defense, automotive, aerospace and industrial sectors extend the life and capability of their presses. Each retrofit tells a story of improved performance, reduced downtime and renewed confidence in production.
An 800-ton Verson metalforming press was repurposed for a high-speed hot stamping application. The original frame and major mechanical components were structurally sound, but the hydraulic and control systems required a complete re-engineering effort to achieve the rapid stroke and precise pressure control demanded by hot stamping.
Macrodyne’s engineering team performed a full hydraulic and control system retrofit, including:
New accumulator-based hydraulic drive package mounted on the press for high-flow operation and rapid press cycling.
Triple pre-fill system with top-mounted tank and proportional control for fast approach speeds and accurate pressure transitions.
New pressing manifold with logic-valve technology, proportional speed and pressure control, and integrated safety valves.
Integration of new throttle and pre-fill valves to optimize flow through the cylinder bores.
Re-use and re-integration of select components, including the existing hydraulic unit (for flow assist and cooling), press controls, light curtains, and guarding, ensuring cost-effective modernization.
Electrical retrofit featuring a new WEG high-efficiency motor, Allen-Bradley starter, updated wiring, and re-programmed PLC/HMI to coordinate the new hydraulic system.
The retrofit delivered hot-stamping-ready performance, transforming a conventional forming press into a high-speed system capable of rapid approach and controlled pressing speeds. The press was later used for tooling tests and process development, achieving precise stroke control and reliable cycle consistency comparable to purpose-built hot stamping equipment.
After severe contamination took out six main hydraulic pumps, Macrodyne supplied, converted, and installed new energy-efficient hydraulic drive units, getting the large-scale press back in operation in just six weeks. It was a rapid response that few others could match.
Despite the scale of the repair and pump size, the press was back in production in just six weeks — a turnaround made possible by Macrodyne’s in-house inventory, engineering capacity and rapid coordination.
A complete hydraulic, electrical and mechanical overhaul of one of the largest presses in service today. Featuring 14 pumps, a 2,100 HP drive system, and full re-piping, this project showcases Macrodyne’s unmatched capability in large-scale press retrofits.
Macrodyne is currently executing a full-scale modernization of an 8,600-ton Watson Stillman press. It’s one of the most comprehensive retrofits ever undertaken by our team. The project involves a complete re-engineering of the press’s hydraulic, electrical and select mechanical systems to dramatically enhance reliability, speed and serviceability.
The system transitions to rapid control, then applies a controlled ramp rate to build pressure quickly without overshoot, preventing damage to the press or tooling.
Hydraulic System Upgrade
Complete removal of the existing hydraulic circuits, manifolds and piping.
Design and installation of four new manifolds with proportional and logic-valve technology.
New energy-efficient hydraulic drive systems (14 in total) powering a 2,100 HP hydraulic system.
Floor-mounted PMG skid, new reservoir, heat exchangers, filtration, and automatic lubrication system.
Prefill tank added on top of the press for improved fill rates and performance.
All new piping and fittings from HPU to auxiliary circuits, pre-bent where practical.
Pump system relocated to a remote service platform for easier access and maintenance.
Electrical & Control System Upgrade
New Compact GuardLogix PLC and PanelView Plus HMI with full re-programming.
Automated pressure and position sensing for all main circuits.
New motors, disconnects, transformers, and cabling throughout.
Integration of new light curtains, safety gate switches, and safety logic.
Re-wiring and new linear transducers for precise position and force feedback.
HMI interfaces for heater-container controls and process data visualization.
Field Work & Commissioning
Multi-stage installation supported by dedicated Macrodyne electrical and hydraulic technicians.
Pre-installation visits to minimize downtime through pre-wiring and system preparation.
Commissioning to include full PLC/HMI setup, hydraulic tuning, and operator training.
With 14 pumps, a 2,100 HP system, and newly designed control architecture, this retrofit represents the future of high-tonnage press modernization. Once completed, the system will deliver improved speeds, tighter process control, and simplified maintenance access.
Behind the 8,600-Ton Retrofit
Go behind the scenes of one of the largest press retrofits ever engineered in North America.
From hydraulics and controls to energy-efficient hydraulic drives powering a 2,100 HP system, see how Macrodyne is transforming an 8,600-ton Watson Stillman press into a modern production powerhouse. [Watch the Video]
Two 1972 presses with more than more than 4 billion cycles received new hydraulics and custom-built cylinders designed by Macrodyne. The modernization boosted cycle speed by 50%, extending the life of these nonstop workhorses well into the future.
For a 2,000-ton press used in tantalum processing, Macrodyne redesigned and rebuilt the crosshead cylinders, engineered an all-new remote hydraulic system, and installed new electrics and piping, modernizing a critical legacy forging line from the ground up.
This retrofit restored full operational capability to a high-tonnage press used for precision forging of refractory metals. The new hydraulic system provided proportional speed and pressure control, improved energy efficiency, and extended service life, ensuring stable production performance for years to come.
Macrodyne re-engineered a 750-ton press, removing one daylight and transforming it into a dedicated pallet press. The retrofit included new hydraulics, controls and safety features, giving old equipment a new purpose.
This retrofit gave a decades-old press a new purpose and extended its productive life , transforming it from idle equipment into a reliable, purpose-built pallet press.
Macrodyne modernized a 1,500-ton powder compaction press with a new remote hydraulic system, reprogrammed controls and shuttle drive integration. The result: smoother operation, improved efficiency and reliable performance in tantalum compaction.
The retrofit delivered smoother, more consistent motion control, improved energy efficiency, and reduced maintenance downtime. The press’s fully reprogrammed control system enabled seamless coordination between hydraulic motion, shuttle drives, and powder handling subsystems, extending the life of a critical compaction line and improving process reliability.
Macrodyne reprogrammed and rewired a 2,700-ton SMS forging press to replace its obsolete PC-based control system. The upgrade introduced modern PLC/HMI controls, new valves, and improved operator functionality, extending the life of a critical forging line.
Scope of Work
Electrical & Control Modernization
The retrofit delivered a seamless transition from an obsolete control platform to a modern, maintainable system. Operators retained familiar control functionality while gaining the benefits of updated automation, improved diagnostics, and easier maintenance. The upgrade extended the operational life of the press and aligned it with the control standards used on newer Macrodyne presses in the same facility.
Macrodyne completely modernized a Korean-built press for a manufacturing facility in Michigan, replacing all hydraulics and electrics with a new 100 HP system and reprogrammed controls. The result: faster cycles, better reliability, and full integration with modern production standards.
The retrofit transformed the press into a modern, high-speed forming system capable of 4-second cycles on a 12-inch stroke, a significant improvement in efficiency and responsiveness. The company gained a robust, fully documented system with improved maintainability, precise control and production flexibility for future tooling and part changes.
Macrodyne upgraded an existing 1,450-metric-ton press with a new energy-efficient hydraulic drive system, improving energy efficiency, control precision, and overall system performance, all completed with on-site installation in Northern Ireland.
Originally built by Macrodyne in the late 1990s for reaction injection molding, this 500-ton press was fully re-engineered into a modern composite press with a new Sytronix energy-efficient drive, hydraulics and controls.
In 2018, Macrodyne completed a full-system transformation of one of its own legacy machines — a 500-ton reaction injection molding (RIM) press originally built in the late 1990s. As RIM technology became obsolete, the press was repurposed and rebuilt as a composite forming system equipped with an advanced Sytronix variable-speed drive for energy-efficient performance.
Hydraulic System Replacement
Electrical & Controls Modernization
The retrofit transformed a legacy RIM press into a state-of-the-art composite press with modern, energy-efficient hydraulics and intelligent controls. The new Sytronix drive reduced energy consumption, noise and heat generation, demonstrating Macrodyne’s ability to revitalize legacy equipment for next-generation manufacturing.
Macrodyne completed a series of small yet critical retrofits for several presses, including safety, hydraulic and pump upgrades across 400-, 750-, and 1,500-ton systems. Proof that no retrofit is too small when uptime and compliance.
These smaller-scale retrofits extended the lifespan, safety compliance and performance of multiple customer presses while minimizing downtime and cost. They highlight Macrodyne’s flexibility — from full system rebuilds to focused component upgrades — and the company’s commitment to engineering excellence at every scale.
The modernization delivered enhanced reliability, safety compliance, and performance consistency across both 750-ton presses. The new energy-efficient drives reduced operating costs, while the updated controls and sealing systems extended equipment life and simplified maintenance.
Macrodyne modernized an 800-ton stretch forming press with new hydraulics, updated valving and a complete electrical and control system rebuild, improving accuracy, reliability and long-term serviceability.
The retrofit significantly improved system responsiveness, diagnostic capability, and precision across all forming axes. With new sensors, electronics, and controls in place, the press now meets modern aerospace manufacturing standards while maintaining the original mechanical foundation.
Macrodyne fully modernized a 2,000-ton compression molding press with new hydraulics, electrics, and controls, integrating an energy-efficient drive and advanced PLC/HMI system for high precision and process visibility.
Macrodyne replaced and reprogrammed the hydraulic pumps on a 3,000-ton compression molding press, upgrading to modern units for improved performance, reliability, and control precision.
Macrodyne modernized a 5,000-ton forging press, replacing all hydraulics and electrics and converting the system from water-based to oil-based operation for improved reliability and control.
Macrodyne rebuilt and modernized two legacy presses and supplied one new 2,000-ton heated platen press, including complete hydraulic, electrical, and automation upgrades.
Macrodyne supports hydraulic, servo-hydraulic, mechanical, forging, forming, and custom-built press systems from a wide range of manufacturers.
Schuler, Verson, Bliss, Clearing, Niagara, Danly, Williams & White, Pacific Press, Erie Press, Greenerd, French Oil
Beckwood, Neff Press, Dake, Enerpac, Wabash, Cincinnati, Sutherland, Betenbender, Savage, Multipress
Aida, Komatsu, Minster, Müller Weingarten, SEYI, Chin Fong, Wilkins & Mitchell, Verson Wilkins, Clearing Niagara
Müller Weingarten, Hydrap, Erfurt, Spiertz, Beche, SMG, Eitel, Beutler
Not seeing your press manufacturer listed That doesn’t mean we can’t help. Many older presses have been modified over time, and some machines no longer match their original documentation. Macrodyne can inspect your existing press, review available drawings and maintenance records, and recommend the most practical repair, rebuild, or modernization path.
Macrodyne supports full and
partial press rebuilds depending
on the condition of the machine,
production requirements, and
available budget.
Services may include:
Let Macrodyne deliver the precision and performance your aerospace manufacturing demands with industry-leading aerospace hydraulic presses and servo presses.
Explore practical articles on hydraulic press rebuilds, press repairs, equipment modernization, controls upgrades, safety improvements, and rebuild-versus-replace decisions for aging press systems.
Your Hydraulic Press Still Runs. That Doesn’t Mean It Still Competes.
An older hydraulic press may still cycle, but that doesn’t mean it’s still competitive. This article looks at the hidden costs of aging press systems, from downtime and safety gaps to outdated controls, inefficient operation, and missed production performance.
Read here
Should You Rebuild or Replace an Older Hydraulic Press?
For older hydraulic presses, the right answer depends on more than age or upfront cost. This article breaks down the practical factors that should guide the decision, from frame condition and safety upgrades to controls, automation, downtime, and total cost of ownership.
Modern production demands more from legacy equipment. A properly engineered retrofit can deliver faster cycles, smarter control, and safer operation—without abandoning machines that already work.
Macrodyne has designed and built many other presses not shown on the website.
80% of our presses are custom designed to meet the specific specification of each client.
Macrodyne has designed and built many other presses not shown on the website.
80% of our presses are custom designed to meet the specific specification of each client.
