GERMANY: As one of the leading manufacturers of aluminum extrusion presses in the world, Presezzi Extrusion S.p.A. designs and builds solutions for high-throughput production environments. Every part of the process must run with precision, stability, and speed to meet demanding production targets.
Their extrusion lines rely on critical applications such as hydraulic pumps and magnetic ovens (ZPE), where drives must handle both rapid dynamic changes and stable operation at very low speeds. In these environments, even small performance limitations can affect output, efficiency, and the ability to meet customer expectations.
The challenge: Outgrowing the limits of the existing drive platform
At one of its customers’ production facilities in Germany, rising performance demands began to push the existing drive platform to its limits.
In hydraulic pump applications, the system needed to handle extremely fast acceleration and deceleration. In the magnetic oven, the system also needed to deliver stable low-speed operation while maintaining high torque to control the heating process.
To continue meeting performance expectations and support their customer’s competitiveness, Presezzi needed to transition to a more advanced drive platform capable of delivering higher precision, stability, and robustness across these demanding conditions.
The solution: A future-ready platform for demanding applications
To address these challenges, Presezzi transitioned to the iC7-Automation drive platform from Danfoss, implementing multiple iC7 drive units across the extrusion line in two power variants tailored to the application.
The iC7-Automation drives deliver improved shaft performance in open-loop control, enabling precise and stable motor behavior without the need for additional feedback devices. This allows the system to maintain high torque at very low speeds while ensuring smooth and reliable operation, which is critical for applications such as magnetic
ovens.
At the same time, the solution supports the high dynamic performance required in hydraulic pump applications, handling rapid acceleration and deceleration without compromising control or stability.
A key part of the setup is the IP54-rated design of the drives, which allows them to be installed close to the application rather than inside cabinets. This eliminates the need for additional cooling, reduces system complexity, shortens the shielded motor cable—enabling cost savings—and allows for a more compact machine design. This aspect of the transition builds on a collaboration between Danfoss and Presezzi that dates to 2017, when Danfoss first introduced IP54 drive solutions as an alternative to traditional cabinet-based installations.
Danfoss plays a key role as a technical partner, working closely with Presezzi to recommend the iC7-Automation platform not only to meet current performance demands but also to provide the scalability needed to support future requirements.
The VFD solution applied to hydraulic pumps delivers energy savings of around 30% compared to the standard solution, which uses variable displacement pumps without VFD control.
Danfoss was selected for its innovative IP54 drive solution, which is very compact and helps enable a flexible and compact machine design, combined with the high efficiency of its products. Excellent responsiveness and high-level technical support, where Danfoss has the role of a true technical partner, were also key factors.
In addition, the product performance is particularly impressive in the magnetic oven application (ZPE), which involves a special motor with unique electrical characteristics. iC7-Automation delivers high torque and high speeds when required, while ensuring precise and smooth control, both at low and high speeds, and even in open-loop operation. Furthermore, thanks to the iC7 drives, Presezzi has significantly extended the operating speed range, achieving excellent performance across the entire spectrum from very low to very high speeds. Previously, optimizing performance at low speeds would compromise high-speed performance and vice versa. The iC7- Automation successfully overcomes this limitation.
The outcome: Consistent high performance under demanding conditions
With the iC7-Automation solution in place, Presezzi achieved stable, high-performance operation across both highly dynamic and low-speed applications.
The system now operates with a cycle time of 12.7 seconds per billet, supporting efficient and reliable production at full capacity. With faster and more consistent cycles, the setup enables higher potential throughput, helping Presezzi meet demanding production requirements.
In addition, the IP54 design contributes to improved energy efficiency by eliminating the need for cabinet cooling, while also reducing installation complexity and motor cable length. Together, these improvements result in a more robust and efficient extrusion setup, capable of meeting current performance demands while supporting future requirements.
We have worked closely with Presezzi for years to optimize performance in demanding extrusion applications. With iC7 drives, we were able to take that a step further, delivering both the control needed for today’s applications and the headroom to support what comes next.
Related products
- Superior low-speed performance due to new original control algorithms
- High torque accuracy with 0-370 Hz frequency adjustments
- Load drooping feature provides even power distribution and consistent performance
- Ability to boost DC voltage with AFE system
- Combines high torque and power in a compact design to minimize footprint
- Designed with Safe Torque Off (STO SIL3) as standard for enhanced safety
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