Grundfos is modernizing an existing 315-ton grid press system in Bjerringbro, Denmark. The aim of the retrofit is to increase system availability, reduce downtime, and future-proof the control, drive, safety, and hydraulic technology.

The system consists of a mechanical press with an automatic tool storage unit, a coil line with a zigzag feed system, and a scrap shear with conveyor-based scrap disposal. After several decades of operation, the existing technology had reached its limits. The system was based on an outdated S5 PLC, spare parts were only available to a limited extent, and faults in tool changing, coil feeding, and the feed system were increasing.

As part of the modernization, KOCH automation replaces the existing control system with a modern S7 TIA automation system. New operator terminals and a central 22-inch IPC in the main control panel improve visualization and make it easier to monitor system status, faults, and production parameters. The coil line and feed system are also upgraded with new sensors, EMG strip guiding, and Siemens servo motors to ensure smooth material flow and precise feeding.

At the same time, the scrap shear is integrated into the new control system and brought up to current safety standards. Emergency stop circuits, safety door monitoring, interlocks, and safe shutdown functions are newly implemented. Floor scanners and light curtains provide an additional modern safety concept.

Another key focus is the renewal of the hydraulic system. With the CytroBox from Bosch Rexroth, the system becomes more energy-efficient, compact, and maintenance-friendly. In addition, new control cabinets are installed and the electrical equipment is comprehensively renewed.

With these measures, the press system at Grundfos is comprehensively modernized both technically and in terms of safety. The system will operate more reliably, efficiently, and with significantly reduced susceptibility to faults. The project demonstrates that a retrofit can be a cost-effective and future-proof alternative to a new installation.