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In the industrial manufacturing sector, there is a limit where, once crossed, you are no longer just a standard sheet metal bending workshop but step into the league of massive heavy industry complexes producing on a global scale. The absolute boss of this limit and mega industry are the 250-ton eccentric press machines, which can control an overwhelming force of 250,000 kilograms in seconds. The toughest metals you can imagine, from aerospace parts to rail system infrastructures, from heavy steel forging to defense industry chassis, are shaped at the base of these giants.
As Karmaksan Machine, standing by industrialists since 1988, we do not only harness this enormous kinetic power of 250 tons, but we transform it into a smart robot that works with the precision of a watch. These specially designed systems possess an unparalleled automation compatibility for factories to create integrated tandem press lines.
Indestructible Integrity: Tie-Rod Body Architecture
The body of an ordinary press might not flex while pressing 25 tons, but physical rules change completely when we talk about 250 tons. The moment this enormous force hits the mold, it tries to tear the machine's body upward. One of the biggest engineering mistakes in the industry is trying to hold this tonnage with standard "C" or welded "H" type structures. As Karmaksan, we are making a revolution with the tie-rod body architecture that eliminates this risk from its roots.
In the Tie-Rod design, the machine body consists of massive steel blocks: the lower table, side columns, and upper crown. These blocks are pressed and locked together by giant steel studs (tie-rods) passing through them and tensioned by heat treatment. In this way, when the machine strikes with 250 tons, there is zero flexing in the body. In heavy industry die cutting operations, this rigidity ensures that your multi-million dollar giant molds work with millimeter tolerances without experiencing the slightest deviation.
Power in the Veins: Central Liquid Lubrication System
As you can clearly see in our image, a 250-ton monster needs flawless blood circulation, namely a lubrication system, to work continuously. The friction heat generated at high tonnage cannot be solved with simple manual lubrication in standard presses. For this reason, we use a fully automatic central liquid lubrication system (centrifugal pump supported), woven with copper pipe matrices and controlled from the PLC screen, in our 250-ton presses.
Depending on the operation of the machine, the system pumps pressurized oil to the crank bearings, connecting rods, and massive bronze slides second by second. If there is a blockage in one of the pipes or the oil level drops, the machine's sensors detect it instantly, stop the ram, and give a "Lubrication Error" on the PLC screen, preventing bearing seizure (burning of the motor and crank) 100%.
Heavy Tonnage Hot Forging and Tandem Line Compatibility
Our 250-ton presses go beyond standard cold forming, where metal is shaped at room temperature, and show maximum resistance in heavy tonnage hot forging operations where steel turns red hot. The Karmaksan machine 250 tons series, whose RPM is reduced and torque is maximized with planetary gear reducers (gear group), crushes giant steel billets in seconds.
It is an excellent team player not only as a single machine but also for integrated factories. In sequential production lines (tandem lines) that you create by lining up multiple 250-ton machines side by side, the machines communicate with each other's PLC brains. When the first machine presses the mold, robotic arms take the part and drop it into the mold of the second 250-ton machine without missing a millisecond. Especially in aerospace press projects where very precise tolerances are required, this unshakable synchronization puts companies one step ahead in global tenders.
Critical Safety Equipment of Our 250-Ton Giants
- Pneumatic-Hydraulic Clutch: To be able to instantly stop this enormous kinetic power, a hydraulic clutch brake group with wear-resistant linings that combines the speed of air pressure and the gripping power of hydraulic pressure.
- Hydraulic Overload Safety: A life-saving equipment that pops the hydraulic oil when the tonnage exceeds 250 tons, releasing the ram and preventing the crank from breaking.
- Motorized Ram and Pneumatic Balance: Balancing cylinders that digitally adjust the stroke distance for giant molds and suspend the weight of the upper mold with air cushions.
- Temperature and Pressure Sensors: Industry 4.0 equipment that instantly measures the heat in the main bearings and stops the system in case of danger.
Mega Press Revision and Facility Renewal
Do you have an old press with a 250-ton capacity? It is a terrible loss for your business to dispose of this massive iron mass that carries the fatigue of years, has a mechanical clutch, worn bearings, and failed occupational safety (CE) tests. As Karmaksan Machine, we have one of the leading mega press revision teams in Turkey.
We completely dismantle your old 250-ton presses in your factory or our facilities from A to Z. We grind the crankshafts with zero tolerance, renew all bronze bearings, cancel that massive old mechanical transmission and add a pneumatic clutch and hydraulic safety instead. That old "scrap", which we equipped with a touch PLC panel, takes its place on your production line just like a machine that left the factory today.
To start the revolution in your production lines and enter the biggest tenders of the automotive and defense industries with a complete machine park, get a quote directly from the manufacturer. You can visit our contact page or instantly discuss technical details with our expert engineers from the WhatsApp support line in the lower right corner of the page.