Crimmitschau, March 2026 — As energy costs continue to rise and sustainability becomes a decisive competitive factor, manufacturers of precision metal-formed parts are increasingly looking for ways to reduce their energy footprint — without compromising on performance or output. One of the most promising frontiers in this area is the intelligent use of servo spindle presses in combination with either shared DC bus systems or capacitor-based intermediate circuit energy storage. H&T ProduktionsTechnologie GmbH (HTPT) is actively engaged in exploring and implementing these technologies for the benefit of its customers.

The Energy Challenge in Modern Press Operations

Traditional press systems — whether mechanical, hydraulic, or pneumatic — are characterized by highly dynamic load profiles: enormous peaks of power demand during the forming stroke, followed by relatively low consumption during return and dwell phases. In conventional AC-based systems, the regenerative energy produced during braking and deceleration is typically fed back into the grid or dissipated as heat through braking resistors — a significant waste of energy.
Servo spindle presses change this equation fundamentally. Their electric servo drives are inherently capable of regenerating energy during deceleration and reverse strokes. The key question then becomes: Where does this regenerated energy go — and how can it be used most effectively?

Approach 1: Shared DC Bus Networks in the Factory

One powerful solution is the integration of servo spindle presses into a shared DC bus (direct current) network within the factory. Instead of converting regenerated energy back to AC and feeding it into the grid — with the associated conversion losses — multiple machines are connected via a common DC rail.
How It Works
When one press decelerates or executes a return stroke, the regenerated electrical energy is fed directly into the shared DC bus. Other connected machines — whether presses, conveyors, or other servo-driven equipment — can immediately draw from this bus to power their own acceleration and working strokes. The energy flows directly between machines at the DC level, bypassing multiple conversion stages.

Key Advantages
Elimination of conversion losses — Energy stays in the DC domain, avoiding repeated AC/DC and DC/AC conversions
Peak load reduction — The DC bus acts as a buffer that smooths out individual machine load spikes, significantly reducing peak demand from the grid
Lower energy costs — Reduced peak demand translates directly to lower grid tariffs and energy bills
Reduced grid infrastructure requirements — A shared DC network can reduce the required grid connection capacity for a multi-press shop floor
Scalability — Additional machines can be integrated into the DC network as production capacity grows
Reduced thermal load — Less energy wasted as heat means lower cooling requirements in the control cabinets and the factory as a whole

Approach 2: Capacitor-Based Intermediate Circuit Energy Storage

Where a shared DC bus network is not available or not yet implemented, capacitor banks — and in particular supercapacitors (ultracapacitors) — offer a highly effective alternative for intermediate circuit energy storage directly at the machine level.
How It Works
Supercapacitors are connected in parallel with the intermediate DC circuit of the servo drive. During the return stroke and braking phases, the regenerated energy charges the capacitor bank rapidly and efficiently. During the next power stroke, this stored energy is discharged back into the drive circuit, supplementing or partially replacing energy drawn from the grid.

Key Advantages
High cycle life — Unlike batteries, supercapacitors tolerate hundreds of thousands of charge/discharge cycles without significant degradation — perfectly matched to the repetitive cycle of a press
High power density — Supercapacitors can deliver and absorb energy very rapidly, making them ideal for the short, high-power bursts typical of press operations
No chemical degradation — Supercapacitors contain no liquid electrolytes and are not subject to chemical aging in the same way lithium-ion batteries are
Reduced peak grid demand — By drawing peak power from the capacitor bank rather than the grid, instantaneous load spikes are flattened
Compact and retrofit-friendly — Capacitor units can often be integrated into existing drive cabinet layouts or mounted as standalone units adjacent to the press
Improved drive longevity — Smoother current profiles reduce stress on drive components, potentially extending their operational life

Comparing the Two Approaches

Both approaches are complementary and can even be combined: capacitor banks at the machine level provide fast local buffering, while the DC bus handles energy exchange across the shop floor.

Why Servo Spindle Presses Are the Ideal Platform

Not all press technologies are equally suited to these energy concepts. Servo spindle presses offer a unique combination of properties that make them the natural choice:
Full programmability of the ram profile — stroke speed, dwell time, and return speed can be precisely tuned to maximize regeneration potential
Bidirectional power flow — the servo drives are designed for regenerative operation as a standard feature, not an afterthought
High forming forces at low speed — the spindle mechanism delivers maximum force exactly where it is needed, without overshooting or energy waste
Process flexibility — the same press can be programmed for very different forming tasks, making energy optimization adaptable to each product

The Business Case: Energy Savings with Measurable Impact

The combination of servo spindle press technology with DC bus networks or capacitor storage is not merely a technical improvement — it represents a compelling business case:
Energy savings of 20–50% compared to conventional press systems are achievable depending on the process and configuration
Lower peak demand charges from the grid reduce fixed energy costs independently of actual consumption
Sustainability credentials — reduced energy consumption directly translates to a lower carbon footprint, supporting corporate ESG targets and customer requirements
Future-readiness — as energy prices remain volatile and regulatory pressure on industrial energy consumption increases, efficient press systems become a strategic asset

HTPT: Your Partner for Intelligent Press Technology

At H&T ProduktionsTechnologie GmbH, we bring deep expertise in servo spindle press technology, drive systems, and process integration. We work closely with our customers to evaluate, design, and implement energy-efficient press solutions — from individual machine optimization to full factory-level DC network concepts.
Whether you are planning a new production facility, expanding an existing line, or looking to retrofit your current press equipment for greater efficiency, we have the know-how to help you get there.

👉 Ready to Reduce Your Energy Costs?
Are you interested in learning more about energy-efficient servo spindle press systems and how DC bus networks or capacitor storage could benefit your production?
Let’s talk.
📧 Visit us at ht-pt.com or contact our team directly — we look forward to exploring the possibilities with you.
More performance. Less energy. Smarter manufacturing.