How to Eliminate Press Downtime with Proper Tonnage Calibration
June 5, 2026
Why Rushing to Clear Press Faults Cost Millions in Downtime—And How to Fix It
August 3, 2026How to Eliminate Press Downtime with Proper Tonnage Calibration
June 5, 2026Why Rushing to Clear Press Faults Cost Millions in Downtime—And How to Fix It
August 3, 2026How to Reduce Press Down Time with Modern Controls and Training
In the metal forming industry, demanding production schedules, complex die setups, and tight quality standards leave zero room for unscheduled press downtime. Yet, stampers across the globe face a common issues, such as legacy presses running on obsolete, outdated control systems. When legacy control components fail, sourcing hard-to-find replacement parts can stall production for days.
At Toledo Integrated Systems, we have dedicated almost fifty years to assisting metal formers in addressing these specific issues. By sponsoring comprehensive press automation and control retrofits, we help close the gap between outdated equipment and current productivity needs, ensuring your stamping lines remain dependable, efficient, and profitable.
The Hidden Costs of Outdated Press Controls
Running older press controls exposes metal formers to operational risks:
- Obsolete Components: Finding replacement parts for legacy platforms becomes harder and more expensive every year.
- Complex Diagnostics: Lack of intuitive Human-Machine Interfaces (HMIs) makes finding fault root causes time-consuming and frustrating for maintenance staff.
- Automation Bottlenecks: Older controls struggle to interface with modern in-die sensors, programmable limit switches (PLS), or auxiliary line automation.
- Data Blind Spots: Outdated systems offer no visibility into production metrics, operational runtimes, or fault logs in real time.
Retrofitting legacy presses with modern control platforms eliminates these vulnerabilities.
How Pridgeon & Clay Cut Downtime with Toledo Integrated Systems
A prime example of modern press control integration comes from global automotive supplier Pridgeon & Clay. Operating over 100 presses worldwide across capacities from 40 to 1,500 tons, their Grand Rapids facility runs high-volume automotive axle, heat-shield, and exhaust components.
To solve persistent issues with obsolete control systems and scarce replacement parts, Pridgeon & Clay launched a proactive controls-upgrade initiative with Toledo Integrated Systems. Standardizing on our Allen-Bradley PLC control retrofits, they modernized nine mechanical presses—including two massive 1,500-ton transfer presses and a 1,000-ton unit.
The Results:
- 2–3% Downtime Reduction: Streamlined control logic and simplified troubleshooting reduced downtime significantly on high-demand press lines.
- Extensive Sensor Management: Our flexible control platform effortlessly manages 30 to 40 in-die and in-press sensors per job, enabling precise timing windows, custom duration settings, and part-presence tracking.
- Seamless Line Automation: Upgraded Toledo controls allowed Pridgeon & Clay to synchronize transfer systems, automate straighteners, integrate servo-driven part-removal arms, and consolidate wash line selection into a single interface.
- Instant Diagnostic Visibility: Maintenance teams and operators can quickly cycle through HMI screens to monitor motor temperatures, lubrication pressure, and active sensor faults.
- Enhanced Security & Data Access: Integrated badge-reader access controls fault resets and job setups, while shop-floor management can monitor production metrics from anywhere.
- Fast Upgrades & Remote Support: Retrofits took just 2 to 3 weeks per press. Furthermore, Toledo’s remote service capabilities allow our technical support team to diagnose and resolve complex issues virtually, bringing presses back online fast without waiting for on-site travel.
Why Choose Toledo Integrated Systems for Your Control Retrofits?
Since 1976, Toledo Integrated Systems has led the industry in force measurement, tonnage monitoring, and complete press control solutions. Whether upgrading a single press or automating a full production line, our systems offer:
- Total Press Control (TPC) & Maximizer Integration: Put all your clutch/brake control, die protection, tonnage monitoring, and programmable limit switches (PLS) in one box with one clean HMI interface.
- Industry-Standard Architectures: Built around trusted Allen-Bradley and standard PLC platforms for easy operation and long-term serviceability.
- Comprehensive Die Protection & Load Monitoring: Prevent costly die crashes and hard hits by integrating our signature tonnage modules and die protection sensors directly into your control package.
- Global Support & Remote Diagnostics: Backed by worldwide field support and secure remote diagnostic capabilities to keep your facility running at peak performance.
Modernize Your Press Room Today
Don't let outdated controls limit your plant's productivity. Upgrading your mechanical and hydraulic presses with Toledo Integrated Systems controls prolongs equipment lifespan, improves operator safety, and guards your profits from unexpected downtime.