When it comes to capacity increase in the industrial manufacturing sector, the dream of most companies is to transition from double-digit tonnages to triple-digit tonnages. Incorporating a high tonnage press machine into your factory's production line massively expands not only the number of parts pressed but also the scale of tenders and projects you can enter. At this point, 100-ton eccentric press models are the industrialist's ticket to the "big league."

With our heavy machinery engineering experience carried from 1988 to the present as Karmaksan Machine, we recreate these massive systems with a capacity of 100 tons for your factories down to the finest mechanical detail. From automotive sheet metal part manufacturers to steel construction companies processing heavy profiles and angle irons, wherever power and high impact resistance are sought, the heavy metal forming presses bearing the Karmaksan signature operate non-stop.

Where Cast Iron Ends: Steel Construction Architecture

A 100-ton force hitting the mold and retracting in seconds creates not just a pressure on the machine, but a severe explosion effect. This massive kinetic energy over time causes microscopic cracks and irreversible flexing in chassis cast using traditional methods (cast iron). Therefore, as Karmaksan, we use monolithic steel chassis (ST-44 / ST-52 steel plates) in the standards of a C-frame heavy-duty press in all our machines of 100 tons and above.

These bodies, which are joined with special gas-shielded welding robots and completely relieved of metallurgical stress in giant heat treatment furnaces, ensure that the press does not flex even a tenth of a millimeter even at the moment of the 100-ton strike. This "zero flex" principle is of vital importance, especially in the use of an automotive sub-industry press where tolerances are very tight. An inflexible body offers you flawless sheet metal cutting, burr-free forming, and a mold life that does not wear out over millions of strokes.

Unforgiving Technology: Pneumatic Clutch and Hydraulic Fuse

As power grows, the risks that need to be controlled also grow. Old-style mechanical clutch systems absolutely cannot be used at these tonnages. Therefore, all our 100-ton productions are equipped with advanced pneumatic clutch technology that complies with CE (European) norms and has a millisecond response time. When the operator removes their hand from the control panel in an emergency, the double-coil safety valve instantly locks the multi-ton ram.

Furthermore, one of the biggest problems encountered in these massive machines is the "press jamming" situation caused by accidentally feeding double sheets between the mold or the entry of excessively thick material. The hydraulic fused press (hydraulic overload protection) system, offered as an option in Karmaksan machines, releases the mechanism by discharging the hydraulic oil inside it in the millisecond when the load on the ram exceeds 100 tons. This system prevents the connecting rod from breaking, the crankshaft from bending, and your invaluable molds from shattering by 100%.

Servo Driver Automation for Continuous Production

Under today's competitive conditions, using a 100-ton press only manually means wasting a large part of its potential. We design our machines as a complete automation center to keep up with your company's production speed. Our machine body and PLC brain have a software infrastructure that can be coupled (integrated) with coil sheet unwinders, straighteners, and servo driven eccentric press lines in seconds.

When you mount your large-sized multi-stage molds (progressive dies) on our expanded T-slotted table, our press runs continuously with synchronization signals coming from the servo driver system. You just connect the coil sheet and collect the finished product at the end of the line. This sheet forming press automation minimizes your business's production costs while maximizing your profitability rate.

Outstanding Technical Equipment of Our 100-Ton Machines

• Motorized Ram (Stroke) Adjustment: The ability to adjust the ram distance in seconds with a motorized system from the digital screen without needing manpower when switching between heavy molds.
• Ram Balancing Pneumatic Cylinders: An air-cushioned balance system that eliminates the sagging caused by the multi-ton ram mass and triples the life of the brake pads.
• Advanced PLC Control Panel: A central electronic brain where you can manage production speed, part count, error codes, and mold memory from a single touch screen (HMI).
• Automatic Dosed Lubrication: A central system that automatically lubricates the crank, connecting rod, and slide bearings during production under heavy industry conditions without leaving it to the operator.

Heavy Press Revision and Modernization Services

If you have old machines with a tonnage of 100 tons or more in your factory that are idle, have completed their working life, or cannot pass occupational safety inspections due to mechanical problems, scrapping them is a huge loss of capital. Karmaksan Machine does not only do brand new manufacturing; it also ranks among the most reliable press revision companies in the sector.

We re-machine the worn crank bearings of your existing old machines, renew their bronzes, and most importantly, completely dismantle the old mechanical system, equipping your machine with a brand new pneumatic clutch and PLC panel system. In this way, your old press returns to your factory fully compliant with current occupational safety norms and as a much more efficient die tryout press or production workbench.

To meet our 100-ton giant power that will break ground in your production lines, to have custom automation lines installed for your company, and to evaluate our commission-free price quotes directly from our workshop, you can visit our contact page right away. You can find answers to your technical questions by instantly reaching our expert engineers from the WhatsApp support line in the lower right corner of our page.