Today, forging industries are moving fast towards Electric Screw Presses, and there’s a strong reason behind it. Let’s understand why 👇

⚙️ Why Mechanical Press Has Higher Forging Cost?

Mechanical Presses are still widely used in many forging shops, but their forging cost is relatively high compared to modern presses.
Here are the main reasons 👇

1️⃣ Impression Type Forging:
Mechanical Presses mostly perform impression die forging, which follows a traditional working setup.
The energy per stroke is fixed and not adjustable, meaning each component receives the same force regardless of its size or requirement.
Result – unnecessary energy loss and shorter die life 🔩

2️⃣ Traditional Crank-Type Design:
Mechanical Presses are built with a crankshaft-type mechanism, which is an old mechanical design.
In this system, the slide movement is limited, and stroke control is difficult to adjust.
This restriction limits the flexibility of forging different-sized parts efficiently.

3️⃣ Limited Shut Height:
One of the biggest drawbacks of Mechanical Presses is their low shut height.
Because of this, it becomes difficult to forge taller or bulkier components such as long shafts, hubs, or thick aluminum billets.
Due to limited working space, the forging load distribution becomes uneven, resulting in lower dimensional accuracy.

4️⃣ Overall Cost Impact:
When energy utilization is low, die wear increases, and frequent setup adjustments are needed —
the forging cost per piece automatically increases.
Hence, mechanical presses are cost-effective only for simple shapes and high-volume production runs.

5️⃣ Higher Operational Cost & Low Flexibility:

Since mechanical presses consume full motor power even in idle condition, the electricity consumption remains high.
Combined with frequent maintenance and limited process control, the overall forging cost per piece increases significantly.

Mechanical Presses are only economical for simple, high-volume jobs — not for modern precision forging needs.

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