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Pressure/velocity remains as main factors in a high pressure die casting machine to produce intricate components from the die. Rejection analysis was carried out in a die casting machine used in producing Aluminum components with a higher rejection rate. Three modifications have been carried out in the basic hydraulic design of the machine to increase the efficiency and in turn reduce the rejection of the components. The three modifications include (i) addition of nitrogen bottle to the system design (ii) Reducing the passage diameter of the Intensifier output (iii) Regeneration of Intensifier output. The first modification resulted with increase in pressure and the second with increase in velocity and finally the third one with optimum increase in both pressure and velocity. This has resulted in the improvement of machine efficiency thereby reducing the overall rejection of the components with intricate design.