www.hpmag.co.uk JANUARY/FEBRUARY 2025 HYDRAULICS & PNEUMATICS VOL. 30 No. 1 JANUARY/FEBRUARY 2025 p44 p32 Advancing mobile equipment with digital and sustainable solutions Early warning signs of conveyor belt bearing problems The future of hydraulic Power Units in a Net-Zero economy p16 ®
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A test for UK manufacturers EDITOR’S COMMENT www.hpmag.co.uk HYDRAULICS & PNEUMATICS January/February 2025 3 Uncertainty in the U.S. is a challenge, but not necessarily a crisis for UK manufacturing. ‘ ’ Trade policy instability is nothing new, but the shifting landscape in the United States poses a unique challenge for UK manufacturers in 2025. With fresh uncertainty surrounding tariffs, supply chains, and investment conditions, businesses must reassess their strategies while the UK Government considers how best to respond. The potential for increased tariffs and a more protectionist stance in the U.S. is of particular concern. If major changes to trade policy materialise, UK exporters could face higher costs, supply chain disruptions, or the need to establish a local presence in the U.S. to bypass trade barriers. For businesses that rely on transatlantic trade, the unpredictability is frustrating, especially given the UK’s relative stability in other markets, including Europe. However, it would be a mistake to see this as purely a problem. While some sectors will need to adjust, others may find new opportunities. If U.S. protectionism drives investment away, the UK could position itself as a stable and attractive alternative for businesses looking for a foothold in international markets. Similarly, with the right government support, British manufacturers could shift focus towards regions where trade relations remain more predictable, such as Asia or Commonwealth nations. This is where Prime Minister Keir Starmer’s approach will be crucial. His government must work to ensure the UK is not caught off guard by sudden U.S. policy changes. Diplomatically, this means securing clear commitments on trade from Washington and reinforcing the UK’s position as a reliable partner. Domestically, it means creating the conditions for manufacturers to adapt - whether through financial incentives, investment in skills, or targeted trade agreements that help offset any losses in the U.S. market. For UK manufacturers, the key is agility. Those who rely heavily on the U.S. should be reviewing their exposure and exploring contingency plans. Businesses with diverse export markets may find themselves in a stronger position, while those looking to expand must weigh the risks and rewards carefully. The lesson from past disruptions is that those who act early will be better placed to thrive. Uncertainty in the U.S. is a challenge, but not necessarily a crisis for UK manufacturing. If handled correctly, the shifting trade environment may offer as many opportunities as risks - particularly for those who are prepared to adapt. Aaron Blutstein Editor
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www.hpmag.co.uk HYDRAULICS & PNEUMATICS January/February 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 Operations Manager: Emma Godden-Wood e| emma.godden-wood@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. 26 30 6 NEWS 16 HYDRAULICS As the demand for sustainable and energy-efficient solutions grows, manufacturers of hydraulic power units (HPUs) must adapt to new technologies and practices. By integrating variable-speed drives, biodegradable fluids, and digital innovations, they can reduce costs, improve system performance, and meet the UK’s stringent environmental goals while staying competitive. H&P reports. 26 PNEUMATICS 30 APPLICATIONS 32 KNOWLEDGE BASE The mobile equipment sector in hydraulics and pneumatics is evolving with the adoption of digital technologies and sustainable practices. H&P reports. 34 INTEGRATED SYSTEMS H&P explores how integrated hydraulic and pneumatic systems are contributing to the automation of food production, driving efficiency and cost savings while simultaneously increasing hygiene practices. 37 BFPA Hydraulics & Pneumatics’ issue-by-issue briefing on current activities and views involving the British Fluid Power Association. 38 COMPRESSED AIR, VACUUM, & GENERATORS 40 SPECIAL REPORTS Health & Safety/ Talking Industry/ Acoustic imaging 45 BCAS Our regular news and events update on the British Compressed Air Society. 46 NEW FACES 47 PRODUCTS & SERVICES DIRECTORY 34 Subscribe for your FREE copy now
NEWS 6 HYDRAULICS & PNEUMATICS January/February 2025 www.hpmag.co.uk Britain’s manufacturers believe the introduction of a formal industrial strategy will significantly boost investment, improve productivity, and help address future skills needs, according to a recent major survey. The findings are drawn from the annual Make UK/PwC Senior Executive survey, which captures the views of senior manufacturing executives on the opportunities, risks, and challenges they face in the year ahead, as well as their outlook for the UK and global economies. The survey highlights manufacturers’ optimism about the benefits of an industrial strategy, despite challenges such as rising costs and the threat of a trade war. A majority of manufacturers see the UK as a competitive place to produce goods, with nearly two-thirds (63%) stating that the opportunities for their businesses in 2025 outweigh the current risks. However, the survey also reveals a divided view on the UK economy, with as many executives expecting it to deteriorate as improve by 2025. In response to these mixed economic signals, manufacturers are demonstrating resilience by prioritising innovation, upskilling, and market expansion. Many companies are turning to new technologies and automation as a means of mitigating rising costs and improving operational efficiency. Make UK is now calling on the Government to urgently detail its plans for a long-term industrial strategy following recent consultations, arguing that such a strategy is crucial to sustaining business confidence and strengthening the relationship between industry and government. Stephen Phipson, Chief Executive of Make UK, said: “Manufacturers have demonstrated their resilience over and over again in recent years and, despite the numerous challenges they face, those that remain innovative and are prepared to invest in new technologies, expanding markets and, most crucially, their people will continue to thrive. But, they can only do this if they are operating in the most favourable business environment and there is little doubt that the next twelve months are set to be immensely challenging in a complex international environment. “To help companies navigate a way through these challenges it is now vital UK Manufacturers see industrial strategy as a ‘game changer’ for investment and productivity that Government sets out as a matter of urgency the immediate and significant priorities as part of its formal industrial strategy given the very clear benefits manufacturers believe this will bring. By doing this, it will help re-boot business confidence and ensure the year gets off on a positive footing in terms of the relationship between industry and Government.” Cara Haffey, Leader of Industrials and Services at PwC UK, added: “While it’s true that UK manufacturers are navigating a complex business landscape – compounded by rising costs – there’s a palpable sense of optimism and resilience underpinning the sector’s trajectory for 2025. This optimism is fuelled by hopes of increasing clarity on the proposed UK industrial strategy, as well as a decisive shift towards technology adoption. The sector is moving from viewing technology as a source of incremental improvements towards acknowledging its power to transform operations. “Additionally, there’s a strong focus on innovation, with companies investing in new product lines and business development to seize growth opportunities. This approach, alongside efforts in product development, upskilling, cost management, and embracing technology, positions manufacturers well to navigate challenges and contribute significantly to national economic growth.” According to the survey, over half of manufacturers (57%) said they would increase investment if a long-term industrial strategy were introduced. Additionally, 43% believe such a strategy would drive productivity improvements, while 42% see it as key to addressing future skills needs. Despite significant pressures, the survey shows that almost half of companies (49%) regard the UK as a competitive manufacturing base, compared with just a quarter who disagree. Moreover, 78% of manufacturers are developing new products, nearly half are deploying new technologies, and over a third (37%) are planning to expand into new markets. However, challenges remain, with the overwhelming majority of companies (92%) expecting employment costs to rise. Additionally, over three-quarters (76%) anticipate increases in other business taxes, while 72% foresee rising logistics and transport costs. Make UK is urging the Government to ease the burden of these cost increases by reducing business rates and introducing further measures to support decarbonisation and energy efficiency.
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NEWS 8 HYDRAULICS & PNEUMATICS January/February 2025 www.hpmag.co.uk Polyhose UK celebrates milestones with Dorset Chamber Membership and unveils growth plans Polyhose UK, an energy conveyance products wholesaler, celebrated over 30 years of Dorset Chamber membership in 2024. From its dedicated warehouse and distribution site in Christchurch, Dorset, Polyhose supplies customers all over the UK with world-class Thermoplastic, PTFE, Rubber Hydraulic, Industrial, Composite, Stainless Steel, Flexible hoses and Fluid Connectors. The company is certified to ISO9001:2015 for sales and distribution, assembly and testing of thermoplastic, PTFE and rubber hoses and associated fittings and components and has been consistently ISO-certified since 1997. Polyhose joined Dorset Chamber in the early 1990s. At the time, the company needed assistance with export documentation and certificates of origin to sell and distribute their products to India, the Middle East, South Africa and Asia. Since then, Polyhose has continued to benefit from Dorset Chamber membership through export documentation assistance and training opportunities. 2024 was also a milestone year for the Chamber, which celebrates its 75th anniversary this year. Accredited by the British Chambers of Commerce, Dorset Chamber is dedicated to supporting the Dorset Business Community with solutions for all sectors and sizes of business throughout Dorset. From international trade services to events, networking or marketing, their mission is to enable better lives through business by creating a vibrant, inclusive, and prosperous community. “Polyhose is very proud to have been a member of the Dorset Chamber for so many years, demonstrating our commitment to the local economy and the Dorset business community,” commented Marc Whibley, Managing Director at Polyhose UK. Ian Girling, Chief Executive at Dorset Chamber, added: “I would like to thank and congratulate Polyhose on their 30th year of membership of Dorset Chamber, with this year being our own 75th anniversary. We’ve been proud to support Polyhose with their export activity and congratulate Polyhose on their huge success over the years.” Alongside its Dorset Chamber membership, Polyhose UK is also a member of the British Fluid Power Association (BFPA), the UK’s only trade body for the Hydraulic and Pneumatic Industries. With customers in Dorset and across the UK, Polyhose products are used in all kinds of fluid transfer applications, including hydraulic systems in manufacturing, construction, agriculture, automotive, marine, rescue equipment and industrial applications such as water jetting, sewer cleaning, high pressure blasting and painting and fire suppression systems, as well as LPG and high-pressure industrial gas transfer. In addition to this milestone, Polyhose is also undergoing an exciting period of growth, marked by the recent appointment of Mark Saunders as the company’s new Operations Manager. Mark brings over 20 years of production experience to the role, having held senior positions at global manufacturers like Hallite Seals International, where he was involved in production management, planning, and process improvement. With a strong track record of delivering operational efficiencies and driving continuous improvement, Mark is wellpositioned to lead Polyhose’s operations as the company prepares for an exciting future. His leadership will be pivotal in guiding the business through its next phase of growth, which includes the launch of a new warehousing facility, aimed at increasing product range and UK stock holdings. “We have exciting growth plans ahead of us this year, including bringing our new warehousing facility online to accommodate a wider range of products and increase the depth of our UK stock holding,” commented Whibley. “Mark’s skills will be invaluable in helping us achieve these ambitious objectives by enhancing our operational efficiency and empowering our production and customer service teams. He has already made valuable contributions to our business, and we are keen to utilise his unique skill set and experience fully. I wish him a successful and satisfying next chapter in his career as we work together to drive our business forward.” Mark himself is eager to embrace his new role and the challenges it brings. He said: “I am delighted to be moving into a leadership role at Polyhose, working with the directors to drive operational efficiencies whilst getting the best from our dedicated team. People are the key to any successful business, and I look forward to working with my team to ensure they have the skills, tools, and support they need. By bringing our operations team together under my leadership, we can ensure a clear focus on providing the highest customer service standards from order entry through to completion.”
NEWS 10 HYDRAULICS & PNEUMATICS January/February 2025 www.hpmag.co.uk Linde Hydraulics Limited has officially changed its name to LHY Powertrain Limited. The rebranding marks a significant step in the company’s ongoing transformation, as it shifts from being a component manufacturer to a full solution provider. The name change comes after the company’s 120th anniversary in 2024, a milestone that not only celebrates its rich history but also looks forward to its future. The new name, LHY Powertrain, better reflects the company’s expanded product offering, which now extends beyond hydraulics to encompass a wide range of technologies and complete drive systems. This evolution is aimed at providing customers with holistic solutions for their drive systems, rather than just individual components. The rebranding also includes changes to the company’s online presence. LHY Powertrain’s new website can be found at www.lhy-gb.com , and all email addresses will be updated accordingly. LHY Powertrain traces its origins to the hydraulics division of Güldner-MotorenGesellschaft, which was first established as a manufacturer of tractors. The company began equipping its vehicles with hydrostatic drives, eventually expanding to serve external customers in the 1960s. Over the decades, Linde Hydraulics, as it was known for much of its history, grew steadily, ultimately becoming an independent company in 2013. Today, LHY Powertrain is a leading technology provider in high-pressure hydraulics. Its products are renowned for their ability to reduce fuel consumption and CO2 emissions. With a presence in over 50 countries and a network of approximately 80 sales and service partners, LHY Powertrain is wellpositioned to continue setting industry standards. As the company transitions into its new identity, its mission remains clear: to “Turn Power into Motion.” With a focus on innovation and customer-centric solutions, LHY Powertrain is committed to shaping the future of drive systems while maintaining its dedication to quality and performance. Linde Hydraulics rebrands as LHY Powertrain PEMAC joins Elecosoft to enhance asset management and digital transformation solutions PEMAC, a leading provider of cloud-based computerised maintenance management software (CMMS) has announced it has joined the Elecosoft group which specialises in software solutions for the building lifecycle. The companies say this collaboration brings together two complementary solutions, enhancing PEMAC’s ability to support Irish and international customers in optimising asset management and maintenance processes across industries including life sciences, healthcare, and manufacturing. PEMAC says the partnership with Elecosoft underscores its commitment to delivering innovative, integrated software solutions that drive productivity, safety, and compliance. PEMAC, headquartered in Cork with offices also in Dublin, provides CMMS solutions to over 100 blue-chip international companies, with particular strength in life sciences and healthcare, which account for 42% of its revenues. Notable customers include Coca Cola, Gyproc, Heineken, Wyke Farms, Keppel Data Centres, Stryker, SteriPack Group, LumiraDx, and Amgen. The partnership with Elecosoft’s ShireSystem complements PEMAC’s existing PEMAC ASSETS CMMS platform, combining two powerful solutions to meet the growing demand for digital transformation of asset management in Ireland and internationally. PEMAC’s focus on regulated sectors like life sciences, pharmaceuticals, and healthcare aligns with Elecosoft’s strategy to support industries that require high levels of compliance and efficiency. Adrian Whyte, PEMAC Operations Director, commented: “We are incredibly excited to join forces with Elecosoft and become part of their growing global presence. This partnership presents a fantastic opportunity to expand our reach, offering our innovative CMMS solutions to even more businesses in Ireland and beyond. With Elecosoft’s resources and expertise, we look forward to strengthening our service offerings and helping more organisations improve their asset management and operational efficiency. We’re also excited about the potential for increased future investment in PEMAC from the international Eleco Group.” Jonathan Hunter, Chief Executive Officer of Eleco, added: “We are excited to welcome PEMAC, a highly respected Irish company comprising an accomplished and talented team, into the Eleco family. PEMAC’s strong reputation in Ireland and its deep relationships with local clients are key to accelerating our growth in the region. Together with our building lifecycle software brand, Elecosoft, this acquisition enables us to offer even more advanced asset management solutions to Irish businesses, helping them increase productivity, safety, and compliance. “Ireland is an attractive market for Elecosoft as it already services many wellknown construction and manufacturing businesses, and we’re excited to expand our presence here as digital transformation continues to drive productivity, safety and compliance. This acquisition not only strengthens Eleco’s capability but allows it to positively contribute to the development of Ireland’s PropTech industry.”
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NEWS 12 HYDRAULICS & PNEUMATICS January/February 2025 www.hpmag.co.uk Building on the success of the 2024 event, which attracted 13,500 visitors as well as more than 450 exhibitors and 200 speakers and was named Best Tradeshow at the Conference & Events Awards 2024, SMW 2025 is poised to deliver an even larger, more ambitious, and more transformative event, with more international manufacturers and engineers expected to visit this year. Free visitor registration is now open and a limited number of Premium Plus Visitor passes are available to be purchased. To register visit: https://bit.ly/4iy8LxT Reflecting on the 2024 event, Malcolm Greenhill of Charter Controls, said, “This is the best exhibition we’ve ever done, and I’ve been participating in exhibitions at the NEC since 1983.” Charter Controls From factory floor hacks to future trends: Smart Manufacturing Week 2025 returns to SMW in 2025 as a Platinum Partner, underscoring its trust in the event. Emphasising the ‘must see’ nature of the event is the presence of prominent exhibitors including Schneider Electric, FANUK UK, 3M, Epicor, Binder UK, Cembre, Charter Controls, Ericsson, Hoffmann Group and ifm Electronic. Alongside other big names the exhibition floor will showcase the most influential players in industry. Amongst these giant technology players are cutting-edge startups and the innovative small businesses set to revolutionise the sector. At the heart of Smart Factory Expo, Innovation Alley will feature emerging manufacturing technologies with exhibitors across four key categories: ‘People’ focusing on Wellbeing, Workforce Management, Recruitment and Training and Skills, ‘Product’ which centres in on Design, R&D and Materials, ‘Process’ which includes Productivity, Resilience, Supply Chain and AI and ‘Planet’ which encompasses NetZero, Sustainability and Energy Management. Following the success of 2024, where attendees engaged with groundbreaking solutions from the next wave of tech and consultancy businesses, the 2025 event will provide opportunities to meet start-ups and earlystage companies and their founders, uncovering transformative technologies that promise to shape manufacturing over the next decade. Visitor Trails offer an exciting way to The NEC Birmingham will once again play host to Smart Manufacturing Week (SMW) the UK’s largest festival of advanced manufacturing and engineering on 4–5 June 2025. SMW brings together a powerful lineup of events, including Smart Factory Expo, Maintec, Drives & Controls, Design + Engineering Expo and the Air-Tech and Fluid Power and systems zones. H&P reports.
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NEWS explore the vast show floor, guiding attendees to the most relevant exhibitors and must-see presentations. From Automation & Robotics to Sustainability, Industrial Data & AI, and Product Innovation & Design these thoughtfully curated pathways make it easy to navigate the show and ensure visitors won’t miss out on what’s important. The free educational programme is comprehensive with seven solutions theatres dedicated to addressing a wide array of topics including; Digital Transformation, Industrial Data & AI, IIoT & Connectivity, Design & Innovation, Automation & Robotics, Leadership & Strategy and Maintenance. New this year is the Technology Showcase Theatre, where visitors can see and get their hands on an array of cutting-edge innovations. Offering a rare glimpse into future developments and prototypes, the theatre will feature everything from advanced robotics to wearable technologies, bringing the next generation of breakthroughs to life. In addition, SMW 2025 will continue its commitment to inspiring the next generation of engineers and manufacturers through its dedicated STEM Programme, sponsored by returning Platinum Partner FANUC. Now extended to focus on school year students, as well as those in further education, hundreds of students and apprentices will have the chance to interact directly with industry experts, offering a hands-on introduction to the exciting world of advanced manufacturing and engineering. As in previous years 2025 will also play host to several satellite events, such as The Manufacturer Top 100 Awards and the Manufacturing Digitalisation Summit. This two-day conference for senior leaders, which attracts many of the top 250 manufacturers from across the UK, is focussed on the application of digital technologies to enhance the processes, efficiencies, and outcomes of the manufacturing industry. On the fun side the much-loved Guitar Legends competition will make a return – with a 3D printed guitar to be awarded to the winner - and adding to the festival atmosphere, The Shadow Monkeys will return with their signature high energy and crowd-pleasing hits to close out the first evening’s visitor party. For those with entrepreneurial ambitions, this year’s event introduces an exciting new feature: ‘Smart Tank’. Designed to inspire and empower budding innovators, this platform invites entrepreneurs to pitch their business ideas and product concepts to a panel of industry experts. Additionally, event attendees can explore the dedicated tech demo area, where innovative solutions will be showcased, offering a detailed look into some of the most exciting developments in technology. Smart Manufacturing Week continues to prioritise sustainability, returning as a carbon-neutral event in 2025. In collaboration with Forest Nation, the organisers have pledged to plant one tree for every attendee, a practice introduced in 2023 that has helped reduce the event’s environmental impact while supporting global reforestation efforts. “Smart Manufacturing Week 2025 is laser focused on the visitor experience while ensuring exhibitors have the best opportunity to connect with their target customer base. We create a festival type atmosphere that is entertaining as well as a fantastic opportunity to connect businesses, encourage innovation, and create a platform for industry-shaping conversations.” said Managing Director, Grace Gilling. Smart Manufacturing Week will be taking place at Birmingham’s NEC on the 4th and 5th of June 2025. Other exhibitions are also taking place at the NEC at the same time, and these include Automechanika run by Messe Frankfurt; Med-Tech Innovation Expo and TCT 3Sixty from Rapid News Group and Subcon from the Mark Allen Group. One visitor badge provides access to all events. Register now for free to secure your place at the UK’s most anticipated manufacturing event of the year: https://bit.ly/4iy8LxT For more information and updates, visit www.smartmanufacturingweek.com 14 HYDRAULICS & PNEUMATICS January/February 2025 www.hpmag.co.uk
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HYDRAULICS As industries across the UK face increasing pressure to reduce their environmental impact, manufacturers of hydraulic power units (HPUs) are prioritising energy efficiency and sustainability in their designs. Hydraulic power units are central to a wide range of industrial applications, from construction and manufacturing to oil and gas and renewable energy. In these sectors, HPUs play a vital role in powering machinery and systems that require high force and precision, making the drive for more sustainable operations all the more critical. For manufacturers, this focus on energy efficiency isn’t just about meeting regulatory demands; it’s an opportunity to optimise processes, improve product performance, and ensure long-term competitiveness. Traditionally, hydraulic power units have been known for their high energy consumption. Conventional systems, especially those using fixed-speed pumps, can waste significant amounts of energy. The need for more efficient energy use is becoming increasingly urgent as businesses look to reduce operating costs and comply with stricter environmental regulations. One of the most significant advancements in HPU technology has been the introduction of variable-speed drive (VSD) systems. These systems allow the pump speed to adjust according to the load, ensuring that only the necessary energy is used at any given time. This can result in substantial energy savings, particularly in applications where the load fluctuates, such as in construction machinery or manufacturing processes. While the initial investment in VSD pumps and motors may be higher than in conventional systems, the long-term benefits far outweigh the upfront costs. For manufacturers of HPUs, this presents an opportunity to offer more energyefficient solutions that deliver a quicker return on investment for end users. By integrating VSD technology into their power units, manufacturers not only help clients lower energy consumption, but also reduce wear and tear on components, leading to longer service life and less frequent maintenance. Energy efficiency is just one aspect of sustainability within the hydraulic power unit market. The environmental impact of hydraulic systems goes beyond energy use to include the materials and fluids that power them. Hydraulic fluid, a key component of any HPU, can be harmful if 16 HYDRAULICS & PNEUMATICS January/February 2025 www.hpmag.co.uk As the demand for sustainable and energy-efficient solutions grows, manufacturers of hydraulic power units (HPUs) must adapt to new technologies and practices. By integrating variable-speed drives, biodegradable fluids, and digital innovations, they can reduce costs, improve system performance, and meet the UK’s stringent environmental goals while staying competitive. H&P reports. Driving sustainability: The future of hydraulic Power Units in a Net-Zero economy it leaks or spills, potentially contaminating soil and water. To address this concern, manufacturers are increasingly developing biodegradable, non-toxic fluids that perform at the same high level as traditional oils but break down quickly in the environment. These new fluids help minimise the environmental risk of hydraulic operations, making them a more sustainable option for industries such as agriculture, mining, and offshore oil and gas extraction, where environmental regulations are becoming more stringent. Furthermore, the trend towards sustainability is encouraging manufacturers to adopt a more circular approach to production. Hydraulic power units consist of various materials, many of which can be recycled. Steel, for example, is commonly used in the construction of power packs and can be reused in the production of new units or other components. By considering the full lifecycle of their products, from sourcing raw materials to end-of-life disposal, manufacturers can significantly reduce their environmental impact. The adoption of these circular economy principles not only helps preserve resources but also
aligns manufacturers with the growing demand for eco-friendly products. Net-Zero In the UK, the government’s commitment to reaching net-zero emissions by 2050 has further fuelled the need for sustainable practices in industries like hydraulics. This legislative push is an important motivator for manufacturers to invest in green technologies and solutions. The hydraulic power unit market, by adopting energy-efficient components and environmentally friendly materials, is positioning itself to meet these long-term environmental goals. For manufacturers, embracing sustainability isn’t just about compliance—it’s an opportunity to future-proof their products and remain competitive in a rapidly changing market. The integration of digital technologies also plays a key role in improving the sustainability and efficiency of hydraulic systems. The rise of the Internet of Things (IoT) and smart sensors in hydraulic systems is enabling real-time monitoring and predictive maintenance. These technologies provide manufacturers with valuable data that can be used to optimise system performance, identify inefficiencies, and extend the lifespan of equipment. For example, predictive maintenance can prevent unnecessary repairs and part replacements, reducing waste and downtime. Moreover, IoT integration allows for greater control and monitoring of energy use, enabling operators to optimise their processes further, reducing overall energy consumption and emissions. The push towards sustainability and energy efficiency is not just a trend—it is becoming a core aspect of the hydraulic power unit sector. Manufacturers who invest in energy-efficient solutions, biodegradable fluids, recyclable materials, and digital technologies will not only improve the performance and lifespan of their products but will also enhance their standing in an increasingly environmentally-conscious market. Customers, particularly those in industries such as construction, oil and gas, aerospace, and manufacturing, are more aware of the environmental impact of the products they use. By prioritising sustainability, manufacturers can meet these demands while also contributing to global efforts to reduce carbon emissions. The road to sustainability may be complex, but the benefits for manufacturers of hydraulic power units are clear. Those who make the transition to greener, more energy-efficient solutions today will not only be ready to comply with future regulations but will also strengthen their market position by offering products that meet the evolving demands of a more environmentallyconscious world. Embracing sustainability is no longer just a matter of regulatory compliance; it’s a strategic move that will ensure the long-term success of hydraulic power unit manufacturers in a rapidly changing industry. 0114 349 0766 • info@plascompo.com • www.plascompo.com ECO RANGE OF PROTECTIVE CAPS & PLUGS Made entirely from second-life plastic Available now…
becoming increasingly important in addressing the diverse challenges faced by different sectors. Heat exchanger demand Looking ahead, the demand for more efficient heat exchangers is expected to grow, driven by the ongoing shift towards sustainable energy practices. As a result, companies in this field are increasingly focused on integrating new technologies to further improve product performance and monitoring capabilities. By keeping up with these developments, manufacturers can continue to provide solutions that help industries reduce their energy consumption and environmental impact. In summary, the role of heat exchangers in industrial processes is undeniable, with ongoing advancements in design and technology helping companies improve efficiency and reduce their environmental footprint. As industries continue to focus on energy management, the role of companies that specialise in thermal technology will remain crucial to supporting these goals. For further information please visit: www.emmegi.co.uk HYDRAULICS Effective thermal management has become an essential focus for businesses aiming to optimise both performance and sustainability. A critical part of this process is the use of heat exchangers, which transfer heat between fluids without mixing them. These components play a vital role in many applications, from cooling systems to temperature regulation across various industries. By improving energy efficiency, heat exchangers can also reduce operational costs and have a positive impact on a company’s environmental footprint. Advanced manufacturing processes Emmegi S.p.A. is one of the companies contributing to developments in this area, particularly in the design and manufacturing of heat exchangers. Established in 1975, the company celebrates 50 years in business this year, having introduced various innovative approaches to thermal technology. Emmegi applies advanced manufacturing processes and high-quality materials to create heat exchangers that are both efficient and durable. Its range of products includes several different types, such as shell-andtube, brazed, and plate heat exchangers, each designed for specific industrial uses. Quality assurance is a key part of Emmegi’s approach, with products being rigorously tested to meet international standards. In addition to this, the company places an emphasis on sustainability by exploring ways to reduce energy consumption in its products. Research and development efforts are aimed at ensuring that its heat exchangers comply with environmental regulations while also supporting energy efficiency. Efficient thermal management plays a key role in many industries. Emmegi S.p.A. is involved in the design and manufacture of heat exchangers that enhance energy efficiency and help reduce environmental impact. The company, which celebrates 50 years in business since its establishment in 1975, focuses on creating customised solutions to meet the varied needs of different sectors. H&P reports 18 HYDRAULICS & PNEUMATICS January/February 2025 www.hpmag.co.uk Advancements in heat exchanger technology for improved efficiency and sustainability Given that each industry has its own unique requirements, Emmegi offers tailored solutions to meet specific operational and thermal needs. This customisation allows businesses to integrate heat exchangers that best suit their processes. It’s an approach that reflects a broader trend in the industry, where flexibility and adaptability are
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20 HYDRAULICS & PNEUMATICS January/February 2025 www.hpmag.co.uk HYDRAULICS Hydraulic pumps remain integral to many industrial systems, from manufacturing plants to heavy machinery in construction, where efficiency and reliability are key. Maintaining these pumps properly is essential for minimising downtime, preventing costly repairs, and ensuring optimal performance over the long term. As hydraulic systems evolve, so too does the approach to their maintenance. Engineers will increasingly rely on advanced technologies to enhance the reliability and longevity of hydraulic pumps, making predictive and conditionbased maintenance the standard. One of the most impactful changes is the widespread adoption of IoT (Internet of Things) and remote monitoring technologies. Sensors now play a pivotal role in providing real-time data on various critical parameters, such as fluid quality, temperature, pressure, and vibration. These sensors feed continuous data to cloud-based platforms, where engineers can monitor the pump’s performance remotely, allowing for predictive maintenance. By analysing trends and deviations in this data, AI-driven algorithms can predict when certain components are likely to fail, enabling engineers to perform maintenance precisely when needed rather than adhering to fixed schedules. This approach not only reduces unnecessary downtime but also optimises maintenance activities, preventing both premature servicing and unexpected breakdowns. The role of artificial intelligence (AI) in hydraulic pump maintenance has become more prominent as AI technologies advance. With the help of machine learning models, engineers can now forecast component wear patterns based on historical and real-time data. These AIdriven tools offer invaluable insights into the pump’s health, helping engineers to pinpoint issues that may not be immediately apparent through traditional inspection methods. For example, patterns of excessive vibration or temperature rise can indicate potential failures in seals, bearings, or internal components. By using these advanced diagnostic tools, engineers can proactively replace worn-out parts before they compromise the pump’s performance, thus extending its lifespan. Another emerging trend in hydraulic maintenance is the increased focus on energy efficiency as businesses face mounting pressure to reduce operating costs and environmental impact. Variable displacement pumps, electronic control systems, and energy-efficient designs are now more common. These technologies allow the hydraulic pump to adjust its performance to match the load demand, reducing unnecessary energy consumption. Engineers should ensure that their maintenance procedures are aligned with energy efficiency goals, regularly checking for signs of wasted energy, such as pump inefficiency or unnecessary fluid flow. Maintaining the optimal operation of these systems not only cuts energy costs but also contributes to the overall sustainability of the operation. Equally important is the growing adoption of sustainable hydraulic fluids. There is a significant shift toward biodegradable and non-toxic hydraulic oils, driven by environmental concerns. These environmentally friendly fluids help prevent harmful contamination of the environment in case of leaks, while also providing effective lubrication and cooling. Engineers should stay abreast of the latest types of hydraulic fluids that offer both high performance and low environmental impact, and ensure they are used according to the manufacturer’s specifications. Regular fluid analysis remains essential, but now with the added benefit of testing for biodegradability and chemical stability, making it easier to assess the environmental impact of the system as well. System cleanliness also remains a key factor in ensuring hydraulic pump longevity. However, with advancements in filtration and contamination management, engineers now have more sophisticated tools at their disposal. The use of highefficiency filters, along with inline monitors that detect particle size and concentration, Hydraulic pump maintenance is evolving with advanced technologies like IoT, AI-driven diagnostics, and energy-efficient systems. Engineers can now take advantage of predictive maintenance, optimise fluid management, and enhance sustainability practices to improve pump longevity, reduce downtime, and ensure efficient operation in increasingly complex industrial environments. H&P reports. Transforming hydraulic pump maintenance with smart technology
allows engineers to better manage fluid cleanliness. Regular inspections of filters and ensuring their timely replacement can prevent contaminants from entering the hydraulic pump and causing damage. Further, the integration of AI-based filtration monitoring can help engineers identify when filters are becoming less effective, thereby preventing damage before it occurs. Another area that benefits from technological advancements is lubrication management. While traditional approaches to lubrication, such as manual monitoring, remain important, today’s hydraulic systems increasingly rely on automated lubrication systems. These systems ensure that pumps receive the proper amount of lubricant at the correct intervals, significantly reducing the risk of over-lubrication or under-lubrication. Engineers should ensure that these automated systems are maintained and calibrated regularly, as improper lubrication is one of the leading causes of pump failure. Additionally, lubrication sensors integrated into the system can alert engineers to any changes in lubricant quality, enabling them to replace fluids before they begin to degrade and cause wear. The role of training is also evolving. With the integration of smart technologies into hydraulic systems, engineers must be well-versed in understanding how to leverage data from sensors and diagnostic tools. In 2025, virtual training and augmented reality (AR) troubleshooting have become crucial components of engineering education. AR systems can overlay digital information onto real-world environments, allowing engineers to perform complex maintenance tasks with step-by-step guidance. By having access to these digital tools, engineers are able to improve the accuracy and efficiency of their work, making the process of diagnosing and repairing pumps faster and more reliable. While technology continues to enhance hydraulic pump maintenance, the fundamentals of maintenance still apply. Regular checks for leaks, pressure and temperature monitoring, and the early identification of wear through visual inspection continue to be important. Ensuring that pumps are operating within their designed parameters is crucial, and engineers should remain vigilant for signs of irregular operation. Identifying these early warning signs and addressing them swiftly can prevent more significant issues from developing. Finally, engineers must stay informed about the latest developments in materials and pump design. The use of advanced alloys, coatings, and wear-resistant materials continues to improve the durability of hydraulic pumps, particularly in high-pressure and high-temperature environments. Understanding the latest materials and ensuring that pumps are designed to operate within the latest performance specifications will allow engineers to make better-informed decisions when it comes time for repairs or replacements. The maintenance of hydraulic pumps in 2025 will likely be shaped by advanced technologies like IoT, AI, predictive analytics, and energy-efficient systems. By making use of these innovations, engineers can take a more proactive approach to maintenance, ensuring that pumps are optimally maintained, minimising unexpected downtime, and extending their service life. Staying up to date with emerging trends in lubrication, fluid management, and system cleanliness, along with embracing training and digital tools, will help engineers ensure that hydraulic systems continue to perform reliably and efficiently for years to come. STAINLESS STEEL HYDRAULIC HOSE AND PIPE FITTING SPECIALISTS We are the leading manufacturer and stockist of stainless steel hose fittings, tube fittings and adaptors. Call one of our friendly and knowledgeable specialists today to see how we can help. 30 TRADING FOR OVER YEARS CALL 01274 852 066 sales@customfittings.com www.customfittings.com PROUDLY MADE IN THE UK
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