Above: Greenerd designed, engineered and built a 2500-ton compression molding press with 10-ft.- square heated platens maintaining 500-degree (Fahrenheit) surfaces to +/- 5 degrees.
November, 2025- Despite their massive size, NFL offensive linemen rely on coordinated moves, agility and precise execution to give running backs a stable infrastructure for executing successful plays. Like the “O-line,” Greenerd Press & Machine Co. is helping customers achieve consistent performance under pressure.
Greenerd’s heavy hitters—multi-press production cells and automated custom-built hydraulic press solutions with unlimited tonnage and bed size capabilities—are equipping companies to achieve higher throughput, system-verified output and lower cost-per unit. Supply chain disruptions, technology advances and persistent labor shortages have also spurred the introduction of new quality standards across different sectors prompting manufacturers to adapt.
“We recently built a hydraulic press system for a customer that lost a significant number of their experienced senior personnel, which limited their internal capabilities for integration and automation,” says Ben Richards, design engineer for Greenerd. “On short notice, our team assumed the responsibility to automate their custom press system and provide them with a comprehensive turnkey solution.”
Another job called for Greenerd to provide a customer with a seven-press, three-robot system. “They were able to reduce their labor costs by 75 percent,” he says. “Companies want machines to be hands off as much as possible with minimal maintenance and reduced downtime. Our team is able to develop new equipment solutions to meet a customer’s unique needs.
Greenerd uses a design-to-need approach to provide manufacturers with comprehensive turnkey solutions.
TECH TALK
Greenerd develops and engineers its designs based on in-depth conversations with customers and analysis of their parts and production goals. For example, a multi-robot automation cell built by Greenerd reduced the amount of labor required to produce the same quantity of parts. The press team also fitted the cell with custom end-of-arm tooling that could automatically be swapped out by the robot to run multiple part series. Once the raw material enters the system, sensors on the tooling scan it, determine which part is being run and automatically select the right recipe. Sensors also determine material orientation as it enters the cell, as well as which method to select for part handling.
“We have enhanced our automation by proactively adding sensors and fault detection for a variety of applications,” Richards says. “This allows customers to quickly diagnose issues and get their equipment back up and running with little lost production time.”
This year, Greenerd applied its sensor technology to custom conveyor and shuttle systems for part handling in a punching application. The designs use a wide range of sensor packages to monitor both the machine and the movement of parts to ensure accurate alignment while increasing output.
“We worked with our vendors to manufacture a custom, matched set of roller chains to act as a conveyor system capable of processing multiple different-sized parts without the need to change tooling,” Richards says. “The system is capable of indexing parts between stations quickly and accurately without the extended downtimes that can occur with tooling changes.”
In addition, Greenerd designed a custom gripper and drive system capable of traversing parts weighing up to 4,000 lbs. along a standard roller conveyor.
“This shuttle system accurately positions parts in one of our punching presses to an accuracy of 0.005 in.,” he continues. “For high accuracy, multiple alignment stations throughout the machine hold large, heavy parts in place while they are moving.”
Greenerd designs a wide range of sensor packages to monitor both the machine and the movement of parts to ensure accurate alignment while increasing output.
MULTIPLE PARTS
Labor shortages and limited floor space continue to fuel growing demand for flexible equipment that can run multiple products. Greenerd’s response to customer feedback has resulted in several future proofing solutions. The company designed multiple systems that incorporated quick die-change methods to support rapid tooling changes for different product runs.
“We designed a press that uses alignment cylinders at every punch location so that no matter what size part is being run, the machine will center it with the die and punch,” says Richards. “We also redesigned the customer’s tooling to retain critical geometries while adapting to new retaining methods—a technique that securely holds and locates various components of a die set—for faster changeover.
Greenerd 850-ton straightening press with 63 ft. bed for the U.S. military.
MARKET CHANGES
While the shipbuilding and defense industries have routinely bought heavyweight hydraulic presses, Greenerd sees part applications for its large presses growing in the automotive and aerospace markets. “These manufacturers are using larger amounts of composite and laminated materials,” Richards says. “In one example, Greenerd developed heated platens for a compression molding press that allows a customer to maintain a uniform temperature across the platen within 5 degrees Fahrenheit of the desired set point, while achieving final temperature as quickly as factory constraints allow.”
To help support customers’ development efforts, Greenerd has built research and development (laboratory-style) presses in the last two years for both commercial and U.S. military companies. “With projects like these, we pursue a deep and insightful understanding of the customer’s objectives and products,” Richards says. “This allows us to make even more meaningful recommendations and design choices that improve a project’s overall outcome.”
“As technology evolves, our customers are looking to achieve tighter and tighter tolerances on their products,” he continues. “We also expect demand for energy efficient, sustainable methods of production to grow. There is no one-size-fits-all in the hydraulic press arena. Greenerd’s design-to-need approach starts before the initial quoting process and continues beyond project completion.
“Industries change, company structures shift, even during active projects,” says Richards. “We will continue to work closely with customers to fine tune and enhance the balance between energy efficiency and overall machine cycle time for desired throughput. Greenerd has stood by the quality equipment that we produce since 1883 and nothing will change that.”
Greenerd Press & Machine Co., 603/889-4101, greenerd.com.
