Safety Update for Long-Serving Press – 60 Plus: Old Press as Good as New!
May 5, 2026
Mencarelli Pompe e Valvole S.r.l, an Italian manufacturer of electric pumps and centrifuges based in Bresso near Milan, had an approximately 60-year old, 120-tonne hydraulic press, which was fundamentally sound but no longer state of the art in terms of control technology. In 2025, Mencarelli decided to modernise the press which, although old, was important to the company. The aim of the retrofit was to make the hydraulic press not only safer for operators, but also more intuitive to use.
“For planning and implementation, Mencarelli was looking for a reliable partner with in-depth technical expertise and a clear vision of safety.” With the overall package consisting of a safety and control concept, including the integration of a modern visualisation solution, Pilz Italy upgraded the press to the current state of the art.
Maximum confidence in safety
The first step in this retrofit was to carry out a risk analysis to clarify the potential hazards posed by the press and the measures to be taken to protect operating personnel. In particular, loading and unloading the press involved recognisable risks to the operator. Today, the base unit PNOZ m B1 of the small controller PNOZmulti 2 and the industrial PC IndustrialPI are at the heart of the integrated safety and control solution.
As a soft PLC, it is responsible for the motor’s synchronous axis movements in the press. The open operating side is now equipped with two light barriers PSENopt II: any spontaneous or wilful intervention in the press action area triggers a safe stop of the press ram. The retrofit has retained the familiar structure of the hydraulic press, while the innovative safety and control concept offers the best possible protection, which operators can rely on almost blindly.
Benefits at a glance
- Press retrofit for a machine that’s practically as good as new
- Absolute cost efficiency: maximum 60 per cent of the cost of a new acquisition
- Complete, integrated package comprising a safety, control and visualisation solution, tailored precisely to your specifications
Customer statement
“Pilz has succeeded in integrating modern safety technologies into completely redesigned mechanics, resulting in a machine that’s practically as good as new. Pilz has taken our complex individual ideas and translated them perfectly into a manageable, efficient solution. The co-operation was exemplary from start to finish and they kept within the calculated costs.”
Guido Mencarelli, Managing Director of Mencarelli Pompe e Valvole S.r.l.
About Mencarelli Pompe e Valvole S.r.l.
Officine Meccaniche Fratelli Mencarelli, based in Bresso near Milan, primarily manufactures electric pumps and centrifuges for industrial and civil applications. Founded in 1948 as a manual mechanical business, over the years Mencarelli became an expert in the cold forming of stainless steel. Mencarelli expanded its portfolio once again when Asco Pompe took over the business in 2024. The group of companies operates worldwide, with customers in numerous industrial sectors.
Pilz’s products in the application
Small controllers PNOZmulti
Use the configurable small controllers PNOZmulti to implement multiple safety functions on your plant or machinery. The small controllers can also assume complete machine control on smaller machines.
Safety light curtains
With Pilz’s safety light curtains PSENopt and PSENopt II, you can protect your staff and capital goods – safely, efficiently, and economically.
IndustrialPI – Flexible and versatile!
With the IndustrialPI industrial PC, Pilz supports you in the implementation of the most varied applications in industrial automation. IndustrialPI is versatile, whether purely as an industrial PC, industrial controller (soft PLC) or as an IIoT gateway for your data.
More Information
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Overhead or bridge cranes are an integral part of the production and logistics chain at automotive supplier Marelli Mako Elektrik Sanayi ve Ticaret A.Ş. in the Turkish city of Bursa: the demands on their reliability are high, as the loads suspended overhead must not pose any danger to the operating personnel. When retrofits became due in 2024, Marelli Mako included safety aspects on its to-do list, in addition to optimising productivity and reliability.
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