From Frequent Failures to Steady Performance with ClampMAX® Hydraulic Power Systems
The Challenge: Repeated Pump Failures and Lost Production Time
For years, Modern Advanced Manufacturing relied on conventional high-pressure hydraulic pumps from multiple manufacturers — but the results were costly and disruptive. Frequent overheating caused repeated downtime, and annual replacements became so routine that the team kept spare units on hand to avoid production stoppages.
Previous hydraulic systems — including Enerpac and SPX single-acting portable pumps with remote pendants — were not designed for continuous-duty applications. Likewise, a competitor’s hydraulic workholding system equipped with a conventional pump and motor assembly failed to deliver the necessary thermal stability and durability. Under sustained load, these units experienced excessive heat buildup and accelerated wear, leading to premature failure two to three times per year. Each failure incurred several thousand dollars in replacement costs and up to 30 hours of lost production annually, forcing the team to maintain spare units to mitigate expected downtime.
The Solution: ClampMAX Hydraulic Power Systems
Everything changed when the company switched to ClampMAX® Hydraulic Power Systems from All World Machinery Supply. Purpose-built for demanding applications, ClampMAX delivers consistent performance without overheating. It keeps production moving, lowers replacement costs, and provides peace of mind on the shop floor.
“They hold up a lot better,” said Modern Advanced Manufacturing Supervisor Ozzie Chavez. “These ClampMAXes run like you wouldn’t believe. I’d recommend them to anyone.”
According to Darrell Janesak, Senior Director of Technology at All World Machinery Supply, “ClampMAX gave this customer a reliable, long-lasting solution that keeps production running strong. They found it lasted longer and required far less tinkering. The old units were almost disposable — they’d run their life and then be replaced annually or even sooner, which was costly.”
Today, Modern operates 16 ClampMAX systems, all running continuously since installation.
“We’d absolutely consider adding more in the future,” Chavez said.
A Custom Solution for Motorcycle Manufacturing
All World first introduced ClampMAX to Modern in 2017 for clamping front-end suspension parts for motorcycles in ARROW Workholding Fixtures. Modern needed 5,000 psi clamping pressure in a compact, energy-efficient system that could integrate seamlessly with their robot-tended six horizontal machining centers.
Each ClampMAX system featured:
• Daikin inverter-driven hydraulic systems
• ifm smart sensors monitoring pressure and temperature
• CKD air seat part detection
• PLC machine interface for fixture operations and pressure monitoring
Engineers strategically designed valve stacks to provide precise control over each manifold station, ensuring consistent movement and articulation of the workholding fixtures. It included a vertical stand combining the pump and control panel, saving floor space while offering a fully integrated system. The PLC package enabled Modern to control two fixtures, monitor pressure, and automate clamping/unclamping — all through the machine interface.
Built-In Safety and Operator Protection
Beyond performance, ClampMAX improved safety on the production floor. Earlier pump models used single-hand control systems that left operators vulnerable to potential injury.
“Many of the previous pumps had one-hand control, and safety was an issue because there was the risk of a free hand getting injured,” Chavez said. “ClampMAX systems have two buttons to operate, which account for both hands and prevent injuries.”
This two-hand system ensures that both of the operator’s hands must be engaged to activate clamping, creating a safer and more controlled work environment.
Why ClampMAX Outperforms On-Demand Systems
Enerpac pumps rely on an on-demand design — the motor runs to build pressure and shuts off when the setpoint is reached. While this approach can help limit overheating, it introduces response delays and restricts long-term reliability.
ClampMAX, in contrast, is a live hydraulic system designed for continuous operation. It maintains constant pressure without overheating, shifting into idle speed when full flow isn’t required. The system continuously monitors line pressure, making micro-adjustments in real time. With its continuous-duty design, rapid response, and tight pressure control, ClampMAX provides a robust, production-ready solution for high-pressure workholding applications.
Reliability and Flexibility Designed for Industry
ClampMAX units are built for long-term durability. Their modular design allows each pump system to be reinstalled on another machine or reconfigured with different valve arrangements, all without halting production.
Failures are very rare, but if they happen, All World can turn around a replacement the next day. “We’ve got the inventory, capacity, and people to support our customers,” Janesak said.
The systems are fully tailored to meet each shop’s requirements. Limited space? Integrated automation? Communication with robots or other machines? ClampMAX can handle it all, thanks to close collaboration with robotic integrators and a design philosophy focused on seamless system integration.
The Results
Since adopting ClampMAX, Modern Advanced Manufacturing has:
• Achieved minimal pump-related downtime.
• Eliminated overheating.
• Reduced replacement costs.
• Improved operator safety and control.
Maintained high-performance clamping across demanding production shifts.
For Chavez and his team, the results speak for themselves: ClampMAX has proven to be a reliable, durable, and safe hydraulic solution that keeps production running without interruption.
