Customer: Forge Monchieri, Cividate Camuno (BS)
Sector: Open Die Forgings
Objective:
Forge Monchieri, a well-known company in the industrial forging sector, had in its machine park a press considered strategic for its daily production that presented a complex situation: the press PLC, now obsolete, posed risks in terms of component availability and was no longer efficient for the machining operations.
The main objective was to update the press system, ensuring stable operation and optimising performance in order to reduce cycle times, improve precision and minimise energy consumption. The subsequent phases of the project (still ongoing) also envisage recertification of the installation after the necessary adaptation activities.
Implementation process
- Preliminary analysis and planning:
A thorough analysis of the hydraulic circuit and operational requirements of the installation was carried out, involving the Forge Monchieri maintenance team – which proved highly competent from the outset – in order to identify their expectations and specific requirements. - Software development:
After clarifying the customer’s needs, the Project Group team developed new proprietary software and a new operator interface, specifically designed for the press in use. This phase included the necessary simulations and theoretical tests. - Installation and commissioning:
Once the software had been developed, installation and integration into the press was carried out. Commissioning was particularly challenging: the team worked for three consecutive weeks, without interruption, to meet the deadlines and minimise disruption to the customer. - Operational tests:
The press was subjected to rigorous testing to verify the operation of the new software, with particular attention to precision, speed and reliability. This made it possible to ensure optimal fine-tuning before full operational status.
Operational benefits and results
Precision and speed:
The work cycle speed improved, with an estimated increase of between 15% and 20% compared with the previous software.
Energy savings:
One of the main benefits of the new system was energy efficiency improvement. Thanks to recalibration of the system and optimisation of the number of pumps required, the improvement in electrical efficiency of the P12000 press in terms of kWh/tonne amounts to 20%, with a saving of approximately 1,300 kWh per working day.
Operational continuity:
For Forge Monchieri, this press is considered a strategic element and its operation is essential for the entire production process. With the update, the risk of machine downtime has been significantly reduced, ensuring greater operational continuity and minimising idle times.
Team feedback and response
The outcome of the project was greeted with great enthusiasm by the Forge Monchieri team. The company particularly appreciated the technical expertise and commitment of Project Group, which showed empathy and constant attention towards the customer. This collaborative approach made it possible to effectively address a complex challenge, developing customised solutions even without initial support from the original manufacturer.
The quality of the support and the availability demonstrated created a strong bond of trust, which not only resolved pre-existing problems but also brought the company to a new level of efficiency.
Conclusion
The press optimisation project at Forge Monchieri is an example of how targeted technical management and dedicated support can transform a critical issue into a strength for the customer. Thanks to the new software configuration, Forge Monchieri can now rely on a reliable, precise and more energy-efficient installation, benefiting from a measurable improvement both operationally and economically.
