www.hpmag.co.uk MARCH 2025 p38 p32 Speeding up offshore pump delivery for critical projects How compressed air is shaping a smarter, greener future for industry Keeping production safe and food supply secure p30 How cobots are helping manufacturers overcome the workforce challenge
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Fluid power’s role in a greener future EDITOR’S COMMENT www.hpmag.co.uk HYDRAULICS & PNEUMATICS March 2025 3 The transition to lower-carbon systems is happening, but the role of fluid power—encompassing both hydraulic and pneumatic systems—often remains misunderstood or overlooked. ‘ ’ With the UK’s push towards net zero by 2050, industries across the board are under increasing pressure to decarbonise. While much of the political and media focus has been on electrification, those in the hydraulics and pneumatics sectors know that the reality is more complex. The transition to lowercarbon systems is happening, but the role of fluid power— encompassing both hydraulic and pneumatic systems—often remains misunderstood or overlooked. Hydraulic and pneumatic systems are already highly efficient when used in the right applications, particularly in sectors where high power density is essential. However, the broader push for sustainability means manufacturers and operators are facing increasing scrutiny over energy use, emissions, and environmental impact. From mobile machinery to industrial automation, the challenge is clear: how do we reduce our carbon footprint without sacrificing performance? The good news is that the industry is already innovating. The rise of electro-hydraulic systems, digital controls, and smart energy management is driving greater efficiency across both hydraulic and pneumatic systems. The shift towards biodegradable and lowenvironmental-impact hydraulic fluids and lubricants is another key step in the right direction. In some applications, hybrid solutions— combining hydraulics or pneumatics with electric or hydrogen power sources—are proving to be a practical way to cut emissions while maintaining reliability. However, a gap remains between technical reality and policy direction. Legislation is increasingly favouring full electrification, often without consideration for where fluid power remains the best solution. If the industry doesn’t engage more actively in the conversation, it risks being boxed in by regulations that fail to acknowledge the progress being made in both hydraulic and pneumatic technologies. Rather than seeing net zero as a threat, we should see it as an opportunity to demonstrate the essential role of both hydraulics and pneumatics in a sustainable future. By driving innovation, adopting best practices in efficiency and digitalisation, and working with policymakers to ensure realistic regulations, the sector can remain at the forefront of industrial progress. Aaron Blutstein Editor
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www.hpmag.co.uk HYDRAULICS & PNEUMATICS March 2025 5 CONTENTS EDITORIAL Editor: Aaron Blutstein t| 01732 370340 e| editorial@dfamedia.co.uk Content Sub Editor: Leslah Garland t| 01732 370340 e| leslah.garland@dfamedia.co.uk SALES Sales Manager, UK & Overseas: Andrew Jell t| 01732 370347 e| andrew.jell@dfamedia.co.uk Italian Sales Office: Oliver & Diego Casiraghi t| 031 261407 f| 031 261380 e| info@casiraghi.info Turkey: Intersmart Media meltem@intersmartmedia.co.uk Managing Director: Ryan Fuller t| 01732 370344 e| ryan.fuller@dfamedia.co.uk Production Manager & Designer: Chris Davis t| 01732 370340 e| chris.davis@dfamedia.co.uk Reader/Circulation Enquiries: Perception t| +44 (0) 1825 701520. e| dfamedia@dmags.co.uk Marketing Manager Hope Jepson e| hope.jepson@dfamedia.co.uk Financial Finance Department e| accounts@dfamedia.co.uk Published by: DFA Media Group 192 The High Street, Tonbridge, Kent TN9 1BE t| 01732 370340 e| info@dfamedia.co.uk w| www.hpmag.co.uk In co-operation with Printer: Warners, UK © Copyright 2025, DFA Manufacturing Media Ltd ISSN 1366-1981 H&P is a controlled circulation magazine, published 8 times a year. Please contact DFA Media with any subscription enquiries. Paid subscriptions are also available on an annual basis at £110.00 (UK), £145.00 (Europe) or £180.00 (Rest of the World) P+P included. The content of this magazine, website and newsletters do not necessarily express the views of the Editor or publishers. The publishers accept no legal responsibility for loss arising from information in this publication. All rights reserved. No part of this publication may be produced or stored in a retrieval system without the written consent of the publishers. 28 32 6 NEWS 16 HYDRAULICS 25 BFPA Hydraulics & Pneumatics’ issue-by-issue briefing on current activities and views involving the British Fluid Power Association. 28 PNEUMATICS Pneumatic systems are vital in modern automation but can face common issues like air leaks, pressure drops, and contamination. Understanding these problems and employing effective troubleshooting methods, including ultrasonic leak detection and regular maintenance, ensures optimal performance, reduces energy loss, and prolongs system life in industrial settings. H&P reports. 30 APPLICATIONS 32 KNOWLEDGE BASE A leading pump manufacturer has successfully reduced delivery times by nearly 25% for seawater lift and water injection pumps used in offshore platforms. Streamlined processes and efficient coordination have enabled faster project completion, helping to meet tight deadlines and secure important contracts for two manufacturing sites. H&P reports. 34 INTEGRATED SYSTEMS 37 BCAS Our regular news and events update on the British Compressed Air Society. 38 COMPRESSED AIR, VACUUM AND GENERATORS Compressed air is a proven source of reliable and sustainable power for industrial operations. Now, with technologies such as remote monitoring and AI optimisation, it is set to enter a new era of performance and efficiency. H&P reports. 40 SPECIAL REPORTS Digital Transformation Focus 44 NEW FACES 47 PRODUCTS & SERVICES DIRECTORY 38 Subscribe for your FREE copy now
NEWS 6 HYDRAULICS & PNEUMATICS March 2025 www.hpmag.co.uk Rugby company named Manufacturer of the Year The LISI Aerospace Rugby site, a manufacturer of advanced titanium components for the Aerospace sector has struck Gold at a prestigious national manufacturing awards ceremony. The awards, organised by Make UK, the organisation which represents more than 20,000 manufacturing businesses were held in London to recognise the achievements of regional award winners from across the UK. LISI Aerospace beat off competition from other regional winners and, national category winners, to be named the Make UK Manufacturer of the Year, having already been presented with the national Make UK Developing Future Talent Award. The award was given in recognition of its huge turnaround in business performance as a result of extensive and, relentless efforts, since 2021 to transform its HR, recruitment and working Schneider Electric recently outlined how its global AI positioning unites data science with business domain knowledge to lead the discussion and disrupt industrial automation and energy management. Maria Tjader, Head of Government Affairs UK & Ireland at Schneider Electric said: “AI is not just a technological advancement; it is a strategic enabler that can help businesses enhance efficiency, reduce emissions, and drive economic growth. By integrating AI into industrial operations, companies can future proof their businesses and contribute to the UK’s sustainability and innovation goals.” Schneider Electric’s AI-based solutions, framed in technology ecosystems such as EcoStruxure, transform energy management and automation to achieve both sustainability goals and industrial efficiency. The approach stems from the company’s very own digital journey, is supported by four international AI Hubs in India, France, U.S.A. and China and is actively leveraged by its Industrial Digital Transformation consulting arm. According to the International Monetary Fund (IMF), fully adopting AI could increase productivity by up to 1.5 percentage points annually. If these benefits are realised, they could contribute an average of £47 billion per year to the UK economy over the next decade. After significant advances in technology in the context of Industry 4.0, Schneider Electric is now calling for the potential of AI to be fully harnessed in the industrial space to correctly utilise data, streamline production lines and contribute to predictive maintenance strategies. Schneider Electric’s Sustainability Research Institute has recently released a report on Artificial Intelligence for the Energy Transition to outline AI’s role in transforming energy management, showcasing its potential to optimise demand, reduce peak loads, and facilitate a more sustainable and resilient energy future. François Disch, Digital Transformation Delivery Lead at Schneider Electric, UK & Ireland, highlighted how AI can transform sustainability and efficiency across the industrial sector. He said: “In 2016, Schneider Electric recognised the need to become AI-driven, and shortly after established our Global AI Hub – now AI driving responsible management, industrial automation, and energy efficiency practices with a strong emphasis on diversity and inclusion and, the mental wellbeing of all employees. This has included building extensive links with local schools and colleges, as well as academic institutions and, a focus on opportunities in particular on employees from deprived backgrounds and special educational needs. The other national award winners were: Business Apprentice: Rising Star – Callum Birnie, Bae Systems Business Apprentice: Final Year – Georgia Trelore, Bae Submarines Engineering Apprentice: Rising Star – Molly Smith, Astra Zeneca Engineering Apprentice: Final Year – Harriet Bean, BASF Apprentice Endeavour – Bethany Pedley, Bae Systems Business Growth & Strategy – Tri-Wall Energy & Sustainability – B&M Longworth Ltd Health, Safety & Wellbeing – Safran Seats GB Innovation – Luxfer Gas Cylinders Manufacturing Matters – GA UK / Ideal Heating SME of the Year – Sellectronics Ltd Stephen Phipson, Chief Executive of Make UK, said: “These awards are a testament to the dynamic companies and individuals working within engineering and manufacturing. The sector remains at the heart of creating wealth in the UK and as we grow our economy there will be a bright future for companies and individuals that make the most of their talent.” Mark Capell, General Manager of LISI Aerospace Rugby, added: “To be awarded the UK Manufacturer of the Year marks a major milestone for the Rugby team and demonstrates what can be achieved when you prioritise the development and wellbeing of your workforce; both in terms of employee engagement and business performance. We’re proud to know that we have made a positive impact both on the local community and economy.”
NEWS 8 HYDRAULICS & PNEUMATICS March 2025 www.hpmag.co.uk strong of 350+ AI specialists. This strategic investment enabled us to develop and deploy AI capabilities internally across our own production lines, distribution centres and facilities. Now, we are extending this expertise to assist other businesses to harness AI for industrial automation, energy management and sustainability in the most responsible way possible. Government strategies provide a strong direction for industry and support solutions providers and end users in committing to innovation to reach a more sustainable, profitable future.” Beginners guide to MRO stores outsourcing launched ERIKS, a leading specialised industrial service provider, has launched The Beginner’s Guide to MRO Stores Outsourcing. The free guide is designed to help manufacturers that are considering taking their first steps into outsourcing the management of their MRO (Maintenance, Repair, and Operations) stores in 2025. The guide offers practical advice, based on real experience, to address common concerns and demonstrates how by outsourcing it is possible to improve operational efficiency, accountability, and supply chain control. For many manufacturers, managing MRO stores in-house creates bottlenecks that disrupt production and profitability. According to a recent report (MRO Supply Chain Report – March 2024), over 51% of UK manufacturers reported unplanned downtime due to spare parts availability issues last year, highlighting the hidden costs of inefficiencies. Resource constraints also exacerbate the problem, with 70% of engineering stores staffed by fewer than four people. This often forces engineers to divert their attention from critical maintenance to time-consuming tasks such as sourcing parts, securing quotes, and chasing deliveries. “Outsourcing MRO stores management can feel like a big step for many businesses, but this guide provides a clear and straightforward roadmap,” said Pamela Bingham, CEO of ERIKS UK & Ireland. “It highlights how outsourcing can transform stores operations from cost centres to a key part of a world class manufacturing organisation that plays a key role in increasing production uptime, driving out unnecessary costs and continual improvement in areas such as predictive maintenance and energy use.” The guide explores the challenges of in-house MRO stores management and explains how outsourcing introduces improved structure, transparency, and reliability. By reducing downtime, streamlining inventory processes, and creating greater visibility into MRO operations, outsourcing provides manufacturers with the tools to optimise performance and improve cost control. The guide also covers what happens on taking the first step, starting with an audit of current processes to identify inefficiencies and assess areas where outsourcing can have the greatest impact. By implementing tailored stores management solutions, manufacturers can ensure a smoother transition and realise immediate operational benefits. Manufacturers interested in exploring the benefits of outsourcing their MRO stores management can download The Beginner’s Guide to MRO Stores Outsourcing now from at: https://ow.ly/wsQA50V6JcU VHS Hydraulic Components to exhibit at Hannover Messe and BAUMA 2025 VHS Hydraulic Components Ltd, a manufacturer of hydraulic power packs and supplier of a wide range of hydraulic components, has announced its participation in two major trade exhibitions in Germany in spring 2025. The company will exhibit at Hannover Messe from 31 March – 4 April 2025 and will co-exhibit with its sister companies, Neilson Hydraulics & Engineering Ltd and Parmafluid, at BAUMA from 7 – 13 April 2025. Hannover Messe Hannover Messe is one of the world’s largest trade fairs for industrial technology. At the exhibition, VHS Hydraulic Components will showcase the latest hydraulic product launches from Bosch Rexroth, Casappa, Emmegi, Ikron, Scanreco, Sunfab, and Walvoil. Featured products include the new Sunfab SXM Motor and Scanreco’s innovative G6 range. BAUMA BAUMA is the world’s leading trade fair for construction, building materials, mining machinery, and construction equipment. At BAUMA, VHS Hydraulic Components will coexhibit with its sister companies, Neilson Hydraulics & Engineering and Parmafluid. Together, they will present the latest hydraulic launches from Bosch Rexroth, Casappa, Danfoss, Emmegi, Hydac, Ikron, Scanreco, Sunfab, Walvoil, and Wika. Rob Turner, Managing Director of VHS Hydraulic Components, said: “We are delighted to be exhibiting at both Hannover Messe and BAUMA, where we will be joined by our sister companies, Neilson Hydraulics & Engineering and Parmafluid. These events provide an excellent opportunity to showcase our latest hydraulic solutions and connect with industry professionals from around
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NEWS 10 HYDRAULICS & PNEUMATICS March 2025 www.hpmag.co.uk the world.” VHS Hydraulic Components supplies hydraulic components and solutions to companies in industries such as agriculture, construction, engineering, farming, materials handling, marine, plastics, recycling, and steel. The company also designs and manufactures hydraulic power packs and cylinders at its factory in Sheffield. Visit VHS Hydraulic Components at: Hannover Messe 2025: Hall 005 – Stand G08 BAUMA 2025: Stand A3/529 (with Neilson Hydraulics & Engineering and Parmafluid) For more information about VHS Hydraulic Components, visit https://www.hydraulic-components.net/ Hannover Messe 2025 is set to highlight the latest advancements in smart manufacturing, with a strong focus on automation, artificial intelligence (AI), and sustainability. The event’s Smart Manufacturing exhibition area will span seven halls, featuring companies from around the world demonstrating cuttingedge technologies, components, and integrated Industry 4.0 solutions designed to enhance production efficiency and global competitiveness. The exhibition will cover key topics such as automation, sensor technology, robotics, logistics automation, and drive and fluid technology. AI is expected to play an increasingly significant role in manufacturing innovation. Hubertus von Monschaw, Global Director of Trade Fair and Product Management at Deutsche Messe, stated: “Artificial intelligence will revolutionise the entire value chain of manufacturing companies, significantly boosting their competitiveness. Visitors to Hannover Messe 2025 will gain insights into available and upcoming applications in the market.” Exhibitors in the Smart Manufacturing area will include a diverse range of international corporations, small and medium-sized enterprises (SMEs), and startups. The exhibition will provide insights into industrial sensors, electric drives and controls, AI-supported engineering, and integrated solutions for various industries. Attendees will have the opportunity to explore how these technologies can enhance production processes, balancing productivity with sustainability. The Application Park at Hannover Messe will feature robotics applications, with AI-enabled robots demonstrating their ability to learn tasks and adapt dynamically to changing production environments. Such innovations are particularly beneficial for custom-made products and small-batch manufacturing, enhancing efficiency and flexibility. Drive and fluid technology, traditionally showcased in odd-numbered years at Hannover Messe, will once again be a key focus in 2025 under the Motion & Drives label. Exhibiting companies will present the latest advancements in intelligent and sustainable production technologies. In addition to the exhibition, Hannover Messe will feature a comprehensive supporting programme. The Smart Manufacturing area will host the Industrie 4.0 stage and the Motion & Drives conference stage, both of which are expected to attract significant interest from industry professionals. Hannover Messe 2025 to Showcase Advancements in Smart Manufacturing and AI Dr John Lazar CBE FREng, President of the Royal Academy of Engineering, has received a Knighthood in His Majesty The King’s New Year Honours List for services to engineering and technology. Sir John, a technology pioneer and investor who took up his five-year term as President of the Academy in September 2024, is the first tech entrepreneur to hold the post since the Academy was founded in 1976. He graduated from Oxford University as a Rhodes Scholar with an MSc in Computation and a DPhil in History, following an undergraduate degree in Computer Science at the University of the Witwatersrand in Johannesburg. Sir John is Chair of the Raspberry Pi Foundation, which aims to help young people realise their full potential through the power of computing and digital technologies. Raspberry Pi recently completed a successful IPO of its commercial subsidiary on the London Stock Exchange, cementing an endowment of £500M to drive an ambitious global strategy. He is co-founder, General Partner, and a Limited Partner at Enza Capital, which backs founders and teams using technology to solve large and meaningful problems across Africa. He sits on the boards of multiple African technology companies. He previously served as the Chair of What3words and was awarded a CBE for services to engineering in the Queen’s Birthday Honours list in 2016. He has deep experience of building and managing businesses. He joined Metaswitch Networks in 1987 as a software engineer and became CEO in 2009 and then Chairman in 2015, as the company established its leadership in communications software. He stepped down in 2016 and Metaswitch was acquired by Microsoft in 2020. Royal Academy of Engineering President John Lazar knighted in New Year Honours
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NEWS 12 HYDRAULICS & PNEUMATICS March 2025 www.hpmag.co.uk Smart Manufacturing Week 2025 offers an impressive mix of education, innovation and networking all under one roof. Taking place from 4th-5th June at Birmingham’s NEC, the event gathers participants from the largest industrial businesses through to small start-ups from across the UK and internationally, making it a useful event to attend for anyone in the manufacturing and engineering sectors. H&P reports. Smart Manufacturing Week 2025 With a diverse range of exhibitions, including Smart Factory Expo, Design & Engineering Expo, Maintec, and Drives & Controls, Smart Manufacturing Week covers every facet of modern manufacturing and engineering. In addition, the Air-Tech and Fluid Power & Systems zones, integrated within Drives & Controls, will be of particular interest to Hydraulics & Pneumatics readers, showcasing developments in fluid power and automation technologies. Boasting more than 450 exhibitors and 200 speakers Smart Manufacturing Week offers an unmissable opportunity to explore the latest technology, network with industry leaders and gain insights into how these are revolutionising manufacturing processes worldwide. Fluid Power & Systems and Air-Tech Located within Drives & Controls, the Fluid Power & Systems and Air-Tech zones will showcase interesting new technologies, products and innovations. Exhibitors in these sectors are set to showcase products that enhance precision, reliability, and system flexibility. Technologies, such as compressors, high-precision sensors and hydraulic fittings will be featured prominently. These products are not just improving productivity but also helping to meet increasingly stringent environmental standards. Returning as a gold partner, Teseo will once again highlight its expertise in modular aluminium piping for compressed air and fluid power distribution. Last year, the Italian manufacturer impressed visitors with its precision-engineered systems, designed to improve efficiency and ergonomics across industrial applications. With a strong global presence and a reputation for highquality, certified solutions, Teseo remains a key name in smart fluid power infrastructure. The focus on sustainability, one of the five key pillars of Smart Manufacturing Week, is particularly evident as professionals in hydraulics and pneumatics seek solutions that minimise energy consumption and reduce environmental impact. With the growing push for greener manufacturing and engineering practices, Air-Tech and Fluid Power & Systems are playing a key role in helping businesses navigate this shift. These zones will present valuable insights into how new technologies are driving efficiency while reducing the impact of industrial processes. Other shows at Smart Manufacturing Week There are an abundance of other activities that also take place as part of Smart Manufacturing Week. Outside of the zones, the wider Drives & Controls show will have much to offer including a comprehensive showcase of the latest developments in automation, robotics, and motion control—technologies that are fundamental to the evolution of modern manufacturing and engineering. The Smart Factory Expo is a key feature of Smart Manufacturing Week 2025, providing visitors with the opportunity to discover the latest smart manufacturing technologies. The event showcases a range of hardware and
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NEWS 14 HYDRAULICS & PNEUMATICS March 2025 www.hpmag.co.uk software solutions that address today’s industrial challenges. Design & Engineering Expo is also part of Smart Manufacturing Week, bringing component suppliers together with design engineers to discuss challenging applications and innovative solutions. With a focus on practical applications, it offers workshops and talks from key industry figures, helping visitors stay ahead of trends in design engineering. Lastly, Smart Manufacturing Week is also home to Maintec which focuses on the maintenance solutions crucial for enhancing uptime and operational efficiency. This event offers insight into predictive maintenance, condition monitoring, and automation technologies, all of which directly support fluid power and pneumatic systems. It’s an ideal opportunity for visitors to explore how maintenance innovations can improve system reliability, reduce downtime, and optimise performance. Educational Content Smart Manufacturing Week’s rich educational programme is a major draw with seven free-to-attend ‘solutions theatres’ running during the event. Covering a breadth of topics across smart manufacturing and engineering, these theatres will offer deep insights into emerging technologies, industry challenges, and practical solutions for manufacturers. A standout session for 2025 is by Professor Henrik von Scheel who is widely recognised as the Father of Industry 4.0. Von Scheel, whose work has shaped modern industrial strategy, will take the stage in the Design & Innovation Theatre on the morning of the 4th of June (Day 1) to present a talk on The Future of Manufacturing: Megatrends that Shape the Next Decade. In this session, he will examine the key megatrends that will dominate the manufacturing landscape in the years ahead, including smart automation, AI integration and the evolving dynamics of the workforce. Going onto discuss how manufacturers can capitalise on these shifts to boost productivity, resilience, and sustainable growth. His insights offer a valuable look at the forces that will transform the industry, making this a must-attend for those looking to stay ahead in the fastevolving manufacturing landscape. Bridging the Skills Gap One of the biggest challenges facing UK manufacturing and engineering today is the shortage of skilled workers. Research from 2024 found that 97% of manufacturers recognise that hiring and retaining skilled labour presents a challenge to the growth of their business, with 80% citing that they are struggling to find digital skills. The skills gap is a major focus for Smart Manufacturing Week, so much so that ‘People and Skills’ is one of the five pillars around which the event is organised. The event will explore strategies for attracting and retaining talent, alongside partnerships with organisations driving change. One such partnership is with the Women’s Engineering Society (WES). Susan Robson MBE, Interim CEO of WES, underscores the importance of connecting talent with opportunity: “We know that the engineering sector faces a significant skills gap and fostering innovation is crucial to tackling global challenges like climate change and productivity. Through Smart Manufacturing Week, we aim to bridge the gap between industry and female talent, ensuring that women not only enter engineering careers but also thrive in inclusive workspaces.” Additionally, Smart Manufacturing Week’s collaboration with Women into Science and Engineering (WISE) will focus on broadening the talent pipeline, engaging school-age students and industry leaders alike. Both WISE and WES will be on hand to have these important discussions, offering insights for businesses looking to futureproof their workforce. Smart Manufacturing Week 2025 is a key date in the event calendar for just about anyone involved in any area of the UK manufacturing and engineering sector. With its focus on digitalisation, sustainability, and workforce development, Smart Manufacturing Week 2025 will provide attendees with the knowledge and tools to stay competitive in an ever-changing landscape. From supply chain resilience to the adoption of Industry 4.0 technologies to the maintenance of existing systems, Smart Manufacturing Week will explore the critical trends and solutions shaping the future of manufacturing and engineering as well as some more niche topics that are rarely covered. Visitors benefit from the sheer range of activities available at the event. From education to commercial discussions, networking and the ability to get up close to the technology of the future all surrounded by a fun, exciting and creative atmosphere. With all this under one roof it’s a time efficient way to tick off so many of the ‘to do’ list actions all in an enjoyable, upbeat environment. To find out more or to register to visit Smart Manufacturing Week 2025 please visit: https://www.smartmanufacturingweek. com/
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HYDRAULICS Redashe is recognised for its wide range of hose reels designed for industrial applications. However, what is less commonly known is the company’s ability to offer customised solutions tailored to meet the specific needs of its clients. Dave Butler, UK Sales Manager, Hose Reels, Redashe Ltd, highlights an example of such a request which came from a nuclear power station with an unusual requirement. The initial call was for a spring rewind reel to be made from 316 stainless steel, intended for distilled water – a typical request. However, a critical detail emerged that took the request to a whole new level: the reel would be used to wash down hot fuel rods in a radioactive environment. Butler explains that Redashe’s engineers proceeded with the usual inquiries, asking about hose length, internal diameter, end fittings, water temperature, room temperature, water pressure, and mounting position, taking detailed notes as they went. Then, Butler says a vital question arose: “How will the hose be extended and retracted?” The answer came quickly: “By a robotic arm, of course.” It became clear that the robotic arm would grip the nozzle at the end of the hose, activate the pump, and manoeuvre the nozzle over the fuel rod to cool it before transferring it to the cooling pond for long-term storage. At this stage, Butler says Redashe had not yet committed to the project. Then a glimmer of hope appeared: “We already have a reel, but it recently failed. We have a drawing of it, though we can’t send you the unit—it’s highly radioactive.” At least there was a reference point to begin working from. Redashe could replicate the original design and provide a quotation. However, the next challenge arose: “It was manufactured in 1963, and we have the information on microfiche.” “Oh, and by the way, it must be mounted on the side and match the original dimensions exactly to fit the existing location.” For context, microfiche was once a cutting-edge method of storing technical data—miniaturised images on small transparent film that could be enlarged using a special viewer. It was used widely in the ’60s and ’70s for storing inventories, including parts for vehicles, aircraft, and railways. Today, the closest equivalent might be seen in films where journalists use microfilm viewers to sift through archived newspapers. Butler explains that the team at the nuclear facility managed to extract a photocopy of a photograph of the microfiche and sent it over. Although the original manufacturer’s details were visible, the company had closed down decades ago. Despite the challenge, Butler says Redashe’s engineers worked out the necessary dimensions and reached out to their manufacturing partner, Koreel, based in South Korea. Known for their expertise in delivering complex solutions, Koreel’s team of mechanical, electrical, hydraulic, and pneumatic engineers were up to the task. After extensive discussions between the 16 HYDRAULICS & PNEUMATICS March 2025 www.hpmag.co.uk Custom hose reel solutions for diverse industrial needs Hose reels are essential in many industrial sectors, offering efficient storage and handling of hoses. Beyond standard designs, customised solutions can be created to meet specific operational needs. These bespoke systems help address unique challenges, ensuring optimal performance in diverse environments, from manufacturing plants to specialised industrial operations. H&P spoke to Dave Butler, UK Sales Manager, Hose Reels, Redashe Ltd.
www.hpmag.co.uk HYDRAULICS & PNEUMATICS March 2025 17 three parties, the project was deemed feasible. Within two weeks, a detailed dimensional drawing and costings were prepared, and a quotation was submitted. The proposal was accepted at a competitive price, and production began. From the first phone call to the final delivery on-site, Butler says the entire process took just 12 weeks—not bad for replicating a 60-year-old machine. This case serves as a prime example of the level of precision and custom engineering that Redashe can provide for bespoke applications. In addition to the nuclear project, Redashe has successfully engineered a variety of tailored solutions, including: Electrical cable reels for applications such as the mirror ball motors for Strictly Come Dancing, computer data centres, electric vehicles, and aircraft heater thermostat cables. Spring rewind dual hydraulic reels mounted on backhoe loaders—now available as an optional feature on both civil and military models in the UK and the USA. Fully enclosed, 316 stainless steel, 2” hydraulically powered diesel reels for a port authority. While large-scale production is often the preferred choice, Redashe has shown that a single custom-engineered item can be more affordable than one might expect. For further information please visit: https://www.redashe.com/ YOUR INDUSTRY || OUR SOLUTIONS Explore our range of Hydraulic, Thermoplas琀c, PTFE & Industrial hoses +44 (0)1202 478334 uk@polyhose.com www.polyhose.com Feature rich hoses tailored to meet the needs of the Hydraulic, Je ng & UHP, Torque, Rescue, Paint spray, Gas, Fuel, Pharma & Chemical industries For up to date views and news visit the Hydraulics&Pneumatics website: www.hpmag.co.uk
Wandfluh: Precision and Innovation in Hydraulic and Electronic Solutions Wandfluh, headquartered in Frutigen, Switzerland, has been a leader in hydraulic control solutions since its founding in 1946. The company specializes in designing, developing, and manufacturing high-quality hydraulic control valves, manifold systems, and bespoke assemblies for industrial and mobile applications worldwide. Known for precision engineering and innovation, Wandfluh serves sectors such as industrial automation, aerospace, oil and gas, and mobile machinery. A Legacy of Excellence and Swiss Precision With over 75 years of experience, Wandfluh has built a reputation for producing reliable, efficient, and durable hydraulic components. Its extensive product portfolio includes proportional and switching valves, control electronics, and customized manifold systems. All products are crafted with Swiss precision and undergo rigorous quality control processes. This attention to detail has made Wandfluh a trusted partner for clients who demand top-tier performance. Innovation-Driven Hydraulic and Electronic Solutions Innovation is at the heart of Wandfluh’s success. The company invests heavily in research and development, focusing on advanced hydraulic and electronic solutions that improve performance, efficiency, and environmental sustainability. Wandfluh’s proportional valves with integrated electronics are a key innovation, offering exceptional flow and pressure control for precise hydraulic regulation. Additionally, the company provides intelligent amplifier and controller solutions, which integrate seamlessly with modern automation and IoT platforms. Wandfluh is also a leader in explosionproof hydraulic solutions, offering ATEXcertified valves for hazardous environments such as oil and gas, chemical processing, and mining. These products adhere to strict safety regulations, ensuring reliable operation in high-risk industries. Wandfluh Hydraulics & Electronics Company Profile 18 www.bfpa.co.uk Customer-Focused Approach and Global Reach Wandfluh’s customer-centric approach is integral to its success. By combining deep application knowledge with engineering expertise, the company delivers both standard and customized solutions tailored to specific operational challenges. This focus on meeting customer needs has helped Wandfluh
Wandfluh UK Ltd Northfield Road Southam Warwickshire CV47 0FG United Kingdom +44 (0)1926 810081 sales@wandfluh.co.uk https://www.wandfluh.co.uk/ Contact www.bfpa.co.uk 19 hydraulic systems, the company excels in turning challenging requirements into functional, efficient solutions. Wandfluh emphasizes close collaboration with clients, ensuring each project is customized for the best possible outcome. From concept to completion, Wandfluh prioritizes precision and quality, using the highest quality materials and advanced technologies. The company follows stringent quality control processes throughout production to guarantee reliability and performance, with ongoing support to ensure systems operate at peak efficiency. Wandfluh’s onsite production and machining capabilities are crucial to maintaining precision and quality. The company utilizes state-of-the-art CNC machining and assembly technologies, ensuring high-precision components are produced with exceptional accuracy and efficiency. Each product undergoes rigorous testing and inspection processes, ensuring components exceed customer expectations. maintain its global reach and leadership in hydraulic technologies. Sustainability is a key priority for Wandfluh as it develops energy-efficient solutions for industries moving toward greener operations. The company is exploring new materials, digitalization, and automation to create next-generation products that are more sustainable and efficient. Commitment to Sustainability and Future-Ready Solutions As industries continue to evolve, Wandfluh remains at the forefront of hydraulic and electronic control technologies, committed to shaping the future of fluid power systems with smart, sustainable innovations. Engineering Innovation, Tailored to You Wandfluh specializes in delivering innovative, bespoke hydraulic engineering solutions tailored to meet the exact needs of each client. With years of experience in designing and manufacturing complex By maintaining full control over production and machining, Wandfluh offers flexibility and customization, delivering tailored hydraulic and electronic systems that meet unique client needs. This comprehensive approach ensures clients receive highquality, bespoke solutions efficiently and precisely. Quality Assurance Approval ISO9001-2015 ISO 14001-2015
HYDRAULICS Swaging is a crucial process in the assembly of hydraulic hose fittings, ensuring that hoses are securely attached to their couplings to prevent leaks and failures. However, incorrect swaging techniques can lead to a range of problems, from minor inefficiencies to catastrophic system failures. The importance of precision in swaging cannot be overstated, as any deviation from correct procedures can compromise both the safety and functionality of hydraulic systems. One of the most common issues associated with incorrect swaging is improper crimping pressure. If the crimping force applied is too low, the fitting will not be properly secured to the hose, creating the potential for leaks under pressure. Even minor leakage can lead to reduced efficiency in hydraulic machinery, but in high-pressure applications, this can result in sudden hose detachment, posing serious risks to both equipment and personnel. Under-crimping can also accelerate wear and tear, as even a small gap between the hose and fitting allows for movement and potential degradation over time. Conversely, excessive crimping pressure can be equally problematic. When a hose is over-crimped, the internal reinforcement layers may be crushed or deformed, weakening the overall structure. This can lead to premature failure of the hose, particularly when it is subjected to repeated pressure cycles. Over-crimping can also restrict fluid flow, reducing the efficiency of the hydraulic system and causing unnecessary strain on pumps and other components. The consequences of this kind of failure can be particularly severe in critical applications, such as in construction, manufacturing, or aerospace, where even minor defects in hydraulic assemblies can have significant operational and safety implications. Another frequent mistake in swaging is the improper selection of dies and settings. Each hose and fitting combination requires specific crimping parameters to ensure a secure connection. Using incorrect dies or failing to adjust the crimping machine accordingly can result in a connection that appears visually sound but lacks the required integrity. This is especially problematic in industries where hydraulic systems operate under extreme pressures, as an improperly swaged connection may not show signs of failure until it is subjected to full operational loads. The reliance on visual inspection alone is insufficient; precise measurements and adherence to manufacturer specifications are essential. In addition to equipment settings, the condition of the swaging machine itself plays a vital role. A poorly maintained machine may not apply uniform pressure across the fitting, leading to inconsistent crimping results. Regular calibration is necessary to ensure that the machine is operating within the correct tolerances. Neglecting this aspect of maintenance increases the risk of producing substandard hose assemblies, potentially leading to costly repairs, downtime, and safety hazards. Operator error is another significant factor in swaging-related failures. A lack of adequate training can result in technicians making critical mistakes, such as failing to properly insert the hose into the fitting before crimping or neglecting to clean components before assembly. Contaminants trapped within the fitting can interfere with the sealing process, reducing the effectiveness of the connection. Additionally, variations in technique between different operators can lead to inconsistent quality across assemblies, making standardisation difficult in larger operations. Training and ongoing competency assessments are therefore essential in ensuring that swaging is performed to the required standard every time. The consequences of incorrect swaging techniques extend beyond operational inefficiencies. Hydraulic failures caused by poor crimping can have serious safety implications, particularly in high-risk environments. A sudden loss of hydraulic pressure in a lifting system, for example, can result in uncontrolled movements, endangering both personnel and equipment. Similarly, hydraulic leaks can lead to environmental contamination, especially if the system operates with hazardous fluids. The financial cost of addressing these failures, including downtime, repairs, and potential legal consequences, can be significant, making proper swaging practices a critical consideration for any organisation relying on hydraulic systems. Ultimately, ensuring that swaging is performed correctly requires a combination of appropriate equipment, strict adherence to manufacturer guidelines, regular maintenance, and skilled personnel. Given the potential consequences of improper crimping, investing in proper training and quality control measures is not merely a precaution but a necessity. The integrity of hydraulic systems depends on attention to detail at every stage of assembly, and even the smallest oversight can have far-reaching consequences. 20 HYDRAULICS & PNEUMATICS March 2025 www.hpmag.co.uk The hidden risks of incorrect swaging in hydraulic systems Incorrect swaging techniques in hydraulic systems can lead to leaks, reduced efficiency, and even catastrophic failures. Applying the wrong crimping pressure, using improper dies, or failing to maintain equipment can compromise safety and performance. Precision, training, and adherence to manufacturer specifications are essential to ensuring secure and reliable hydraulic connections. H&P reports.
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HYDRAULICS Ice wipers for hydraulic cylinders are named after their original purpose, i.e. to remove layers of ice or frost from extended piston rods in low-temperature applications. However, such components are increasingly faced with other challenges and it is not uncommon to experience completely torn polymer wipers or bent and destroyed brass wiper lips. Such damage results in ingress of dirt and particles with fatal consequences for the underlying sealing and guide system. The resulting followup costs for removal, maintenance or overhaul and reinstallation of a hydraulic cylinder destroyed by particle ingress can often exceed the original value of a newly delivered cylinder, not to mention downtime. In areas where machines and hydraulic cylinders are continuously exposed to enormous dirt loads, it is essential that attention is paid to the wiper system and that it is adapted as precisely as possible to these conditions. In applications where standard wipers made of elastomers such as NBR or TPEs reach their limits for reasons of strength and wear, so-called metal wipers must be used. Hunger Hydraulic’s wiper type AEIS-SL is a robust solution that has been used successfully for many years. A radially floating primary wiper edge located in the outer retaining ring and designed with clearance is able to follow a piston rod deflected under bending and transverse load and reliably remove even tough or firmly adhering contaminants such as scale, slag spatter, welding beads and even layers of lime from the rod surface. Such harsh conditions are seen in: steel or aluminum plants, in waste compactors, scrap & recycling sectors and often pose major problems for conventional wiper systems. In the standard version of the A-EISSL, the primary wiper edge is made of bronze. However, depending on the application, this can also be made of other metallic or polymer materials. Hunger Hydraulic determines the respective design of the components individually depending on the application and the operating parameters of the cylinder. For example, stainless steel versions are available for the retaining and primary wiper ring for food applications (e.g. agitators, dosing and feed cylinders) as well as highly corrosion-resistant duplex steels for underwater or offshore applications. Suitable metallic materials can also be offered for use in hightemperature applications such as steel foundries. The secondary wiper lip arranged after the primary edge, usually consists of an elastic material which prevents the penetration of dust, very fine residual dirt films or moisture. The materials used for the guide and sealing system (behind the wiper) are thus reliably protected from contamination from harmful fluids (e.g. solvents, water, etc.) or abrasive fine particles. Hunger Hydraulic can also adapt the secondary lip to the different conditions in the application. In the standard version, TPU’s and TPE’s are available in various degrees of hardness and designs (e.g. hydrolysis and microbe-resistant) or vulcanized NBR versions. FKM, H-NBR and FVMQ are available for hightemperature applications. For applications in the low temperature sector, Hunger Hydraulic has a special NBR compound in its portfolio, which can be used down to - 54°C. Wipers for applications where high travel speeds (>1m/s) are achieved, or where extreme demands are placed on chemical resistance and a wide temperature range can be fitted with secondary lips made of corresponding PTFE compounds or high-performance plastics (e.g. PEEK). Depending on the material combination, applications and temperature ranges from -60°C to +200°C can be covered. Following design and material optimization of individual components, Hunger Hydraulic can offer wiper systems that are tailored to function, performance and operating conditions in dimensions from Ø8mm to Ø950mm. For more information please visit: www.hunger-dichtungen.de/home Originally designed to remove ice from hydraulic piston rods, ice wipers now play a crucial role in preventing dirt, wear, and contamination. Advanced designs offer durability and adaptability for demanding environments, ensuring reliable performance across industries such as steel production, recycling, and offshore applications. H&P reports. 22 HYDRAULICS & PNEUMATICS March 2025 www.hpmag.co.uk The evolving role of ice wipers in hydraulic systems
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