Did you know that hydraulic press brakes can run for decades? The reason for their longevity is that they’re made from durable materials, and have the capability of performing high-force bending without putting excess strain on the machine. 

More importantly, businesses are able to use hydraulic press brakes for so long because they have the ability to be repaired or retrofitted when they experience failures or delays in production.

But what actually are these options, and when is each the right move? This article will describe hydraulic press brake repairs, retrofits, and replacements, outline their pros and cons, and help you decide when each is the right option. 

How Do You Know You Need a New Hydraulic Press Brake?

Before we get into what your options are, it’s important to know the signs and symptoms indicating it’s time for you to take action toward a repair, retrofit, or replacement.

Press brakes that need attention may have completely broken down or have experienced declines in production speeds due to inefficiencies, excessive wear, or a part or system failure. 

Whether your entire press brake has stopped functioning or just a component, here are some examples of red flags you might notice, hinting you need an expert to repair, retrofit, or replace your hydraulic press brakes:   

• Frequent breakdowns, leading to rising repair costs
• Inconsistent press performance affecting throughput and lead time (occasional downtime, sacrificed part quality, or increased scrap rate)
• Safety hazards posed to the operator (missing light guards, emergency stops not working, etc.)
  
  

Breaking Down Your Options: What Is a Repair vs. Retrofit vs. Replacement?

Your press brake has broken down – once you diagnose the issue, you can start considering your options. In this guide, we’ll highlight three main solutions:  

• Repairing the press brake
• Retrofitting the press brake
• Replacing the press brake

Repairs, retrofits, and replacements are unique, and are ideal for different malfunctions or inefficiencies. 

Repairing a Hydraulic Press Brake

Repairing a hydraulic press brake involves replacing a basic part. The goal of a repair is to keep the machine running and avoid the upfront cost of a new machine with minimal downtime. 

While similar to what some manufacturers refer to as rebuilding, a repair is generally less extensive.

Retrofitting a Hydraulic Press Brake

Retrofitting is similar to repairing in that they both involve replacing a component, but what makes retrofitting unique is that it consists of upgrading a specific feature– often through the use of a more efficient modern technology. 

Typically, these improvements – such as upgrading the CNC controls with a programmable system or adding predictive maintenance –not only boost productivity and extend the machine's lifespan, but they can also significantly improve operator safety.

Replacing a Hydraulic Press Brake

While repairs and retrofits are great ways to extend the life of your hydraulic press brake, they aren’t always the most cost-effective solution. In some situations, especially when downtime is adding up or your production needs have outgrown your current setup, replacing the machine entirely may be the smarter long-term investment.

New hydraulic press brakes come with faster production speeds, better energy efficiency, and modern automation capabilities. These upgrades can lead to higher output, lower operating costs, and ultimately a better return on investment. If you’re looking to boost productivity and stay competitive, a new machine might be the right move.

Factors Affecting Your Choice of Buying New vs. Repairing or Retrofitting an Old Press Brake

Consider these details will help a hydraulic press brake manufacturer select the best option for you: 

• Age of the machine: How old is your machine? If your press brake is in its later stages, the upfront cost of a new machine or a retrofit may be more valuable than paying for frequent repair costs and downtime for an older press brake. 
• Size of the machine: Larger machines often cost more upfront, making a retrofit a more cost-effective option than a replacement in some cases. 
• Structural condition: If a major part of the machine, like the frame, are damaged, replacement is often a better option, as these parts may not be financially practical, and more . If the structure of the brake is sound, retrofitting may be a good option.  
• Electrical condition: A press brake with a faulty electrical system can often be retrofitted with more modern technology, such as HMI's, CNC controllers, or PLCs. 
• Hydraulic condition: After a number of years, the hydraulic system – including pumps, cylinders, valves, etc. – will likely see wear and tear. These parts can be repaired by replacing the exact component or upgraded with more advanced parts to enhance performance. If the hydraulic system is beyond repair, the manufacturer will notify you that a complete replacement is necessary.
  
  

When Is a Repair vs. Retrofit vs. Replacement the Best Option?

Considering your press brake machine’s underlying issue and the factors that affect the right solution, what are your next steps? Here’s a summary of when each solution may be ideal for an inadequate brake. 

Repair

A repair is best when your hydraulic press brake has experienced a temporary delay due to a defective component that can be replaced with the exact same part. Repairing a press brake is often the most budget-friendly option.  It’s also a quick way to get back up and running with minimal downtime or disruption to your project.

Retrofit

A retrofit is the best option when you’re seeing a decline in the quality of parts being produced. If the machine’s technology is simply outdated and you’re looking for faster, more automated production, a retrofit can be a cost-effective, efficient solution compared to replacing the machine entirely.

Replacement

If your hydraulic press brake isn’t operating, and a manufacturer has determined that a replacement is more practical, a new machine may be your best option. While this may require a larger initial investment, the long-term cost savings of a more efficient machine can outweigh the initial price.

Deciding Whether to Stick to Your Old Hydraulic Press Brake vs. Buy New

Repairing, retrofitting, and replacing an older hydraulic press brake all have their advantages and disadvantages. 

Repairing may be best when you want to reduce downtime and resume operations as soon as possible, while retrofitting may be best when a more automated, efficient technology would benefit your organization. Alternatively, a new hydraulic press brake may be best when your machine isn’t economically irreparable. 

If you’re trying to decide which is the right solution for your new or old hydraulic press brake, speak with a manufacturer to help diagnose the problem and weigh your options. Pacific Press can help you repair, retrofit, or replace your machine. Contact us today to speak with an expert.