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Don’t stand still in the face of trade tariffs EDITOR’S COMMENT www.hpmag.co.uk HYDRAULICS & PNEUMATICS April/May 2025 3 The international picture may remain uncertain for some time, but that doesn’t mean businesses should stand still. ‘ ’ The recent decision by the United States to impose new tariffs - 10% applied to most UK exports, with a more substantial 25% tariff targeting the automotive sector - has added fresh challenges to an already delicate transatlantic trading relationship. For the hydraulics and pneumatics sector, which is closely linked to automotive, industrial machinery, and manufacturing supply chains, the implications are potentially significant. Prime Minister Keir Starmer has pledged support for affected industries, with an emphasis on reducing global trade barriers and developing stronger economic partnerships with the U.S. and other key allies. Discussions are also underway with France, Germany, Canada, and the European Commission to coordinate a broader international response. While those diplomatic efforts are important, UK manufacturers will need to take a proactive approach to navigate the current landscape. For companies in the fluid power industry, this may mean reassessing export strategies, seeking opportunities in emerging markets, and reducing over-reliance on any single trading partner. Demand for hydraulic and pneumatic systems remains strong in areas such as infrastructure, mining, energy, and transport— particularly in regions like AsiaPacific and Latin America, where government trade initiatives could help open doors. There is also a renewed case for improving supply chain resilience. Exploring alternative suppliers, near-shoring key inputs, or using digital tools to monitor risks can help companies respond more effectively to disruption. These steps don’t require a wholesale transformation, but small adjustments now could prevent bigger problems down the line. At the same time, long-term investment shouldn’t fall by the wayside. Automation, energyefficient technologies, and system upgrades not only support productivity but may also qualify for government-backed incentives linked to innovation and lowcarbon initiatives. Collaboration will remain important. Industry bodies such as the British Fluid Power Association (BFPA) are well-placed to represent sector interests and should be part of ongoing conversations about practical support. The international picture may remain uncertain for some time, but that doesn’t mean businesses should stand still. For hydraulics and pneumatics firms, the ability to adapt, stay informed, and continue investing in capability will be key to maintaining momentum in a shifting global market. Aaron Blutstein Editor
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www.hpmag.co.uk HYDRAULICS & PNEUMATICS April/May 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 26 PNEUMATICS Pneumatic control systems are often taken for granted in industrial operations, but they play a crucial role in keeping things running smoothly. For manufacturers in the UK, where competitive pressures, high energy costs, and the drive towards sustainability are ever-present, optimising these systems is a practical necessity. 28 APPLICATIONS Britain’s manufacturing sector faces a critical skills shortage, threatening its ability to apply emerging technologies. H&P reports. 32 KNOWLEDGE BASE 34 INTEGRATED SYSTEMS The increasing integration of artificial intelligence in electropneumatic systems is set to play a significant role in shaping the future of British industry. From predictive maintenance to improved precision and energy efficiency, AI is enhancing manufacturing processes. While challenges like cost and skills gaps remain, this shift promises to optimise operations and drive the future of smart pneumatic automation in the UK. H&P reports. 35 BFPA Hydraulics & Pneumatics’ issue-by-issue briefing on current activities and views involving the British Fluid Power Association. 37 BCAS Our regular news and events update on the British Compressed Air Society. 38 COMPRESSED AIR, VACUUM AND GENERATORS 40 SPECIAL REPORTS SMART MANUFACTURING WEEK PREVIEW MAINTENANCE FOCUS 44 NEW FACES 47 PRODUCTS & SERVICES DIRECTORY 38 Subscribe for your FREE copy now
NEWS 6 HYDRAULICS & PNEUMATICS April/May 2025 www.hpmag.co.uk Hydraulics specialist celebrated for outstanding delivery performance WEBER-HYDRAULIK, a leading hydraulics specialist, has been recognised with the prestigious KION OTIF95 Supplier Performance Award, in acknowledgment of its outstanding delivery performance and close cooperation with the KION GROUP. Introduced in 2023, the OTIF95 Supplier Performance Initiative was designed by the KION GROUP to enhance supplier efficiency and reliability. The OTIF (On-Time In Full) is one of the key indicators of the company’s efficiency in the area of logistics and enables the monitoring of compliance of deliveries to customers in terms of both quantity and punctuality. With the introduction of the Supplier Award, an ambitious target of 95% was set for the most The Engineering Construction Industry Training Board (ECITB) is to invest a further £2 million for Regional Skills Hubs over the next two years. In November 2023, the ECITB announced a £1 million investment to boost training provider capacity and grow new entrant numbers amid significant skills shortages in the engineering construction industry (ECI). The Regional Skills Hub Funding initiative was set up to address these skill shortages by supporting projects focused on enhancing training and skills provision, in particular in the six major industrial cluster regions at the heart of the UK’s decarbonisation agenda. The industrial cluster hot spots are the Black Country, East Coast (comprising Teesside and Humber), North West England, Scotland, South Wales and the Solent. This funding has already helped projects in the Humber region, Teesside, North East Scotland and Great Britain as a whole, with further projects set to be announced shortly. In recognition of the success of the scheme so far and the highquality funding bids being submitted, the ECITB Board has committed to invest more funding to further build training capacity. Andrew Hockey, ECITB Chief Executive, said: “We are delighted with the impact of the Regional Skills Hub Funding initiative. “Our Labour Forecasting Tool predicts that the ECI could need thousands of additional workers over the coming years for major projects, including those that contribute to the country’s net zero goals. “Without a pipeline of trained, skilled workers all this risks not being achieved, which is why we are keen to work with more clients, contractors, training providers and industry partners to invest in growing the number of skilled workers needed for other major engineering construction projects now and in the future. “This extra investment will help further address skills shortages by enhancing training and assessment infrastructure and capabilities at both colleges and independent training providers located in Britain’s industrial heartlands that will directly increase the flow of trained workers into the industry.” The first recipient of Regional Skills Hub Funding was Humber-based training provider, CATCH. It was awarded ECITB invests further £2m in Regional Skills Hubs to tackle industry shortages important suppliers. WEBER-HYDRAULIK has consistently surpassed the target, demonstrating reliability and dedication to its supply chain commitments. Krzysztof Jauernig, Segment Manager of Material Handling, expressed pride in the company’s accomplishment, stating: “The satisfaction of our customers is our top priority. In order to continuously ensure our excellent delivery performance, we as a team react immediately to even the smallest deviations and are always looking for solution-oriented approaches. This proactive and reliable collaboration is of great importance to us, as it enables us to continue to operate at this high level and stand by our customers as a strong strategic partner.”
NEWS 8 HYDRAULICS & PNEUMATICS April/May 2025 www.hpmag.co.uk £300,000 in January 2024 to help upgrade its existing welding, pipefitting and electrical training facilities in Stallingborough near Grimsby. The upgrade to its Welding and Pipefitting Hub, which opened in September 2024, was part of a joint venture with industry to increase learning capacity by 100% over two years. 3t Training Services was the second recipient and awarded £200,000 in October 2024 to support the build of three mobile training units. Two units have already been deployed to deliver training for workers on ECI projects in the North West of England and have the potential to support skills in other areas where there is insufficient training provision. This will create capacity to grow hundreds of new entrants to industry, with the units delivering ECITB-approved courses in mechanical fitting, pipefitting and plating to ECI employers across Britain. The ECITB also worked with industry partners as part of the Net Zero Teesside cluster project, which received a £478,000 funding boost in March 2025 amid growing demand for skilled workers in the region. The funding will contribute to an immersive pipefitting, welding, mechanical and project-based training rig and includes enhanced pipefitting facilities. To find out more about Regional Skills Hub funding please visit: www.ecitb.org.uk/working-for-industry/ regional-skilllshub-funding Polyhose UK, an energy conveyance products wholesaler, was pleased to welcome guests from the British Fluid Power Association (BFPA), Dorset Chamber, Mar-Key Group, Lloyds Banking Group and Rubicon People Partnership to celebrate the official opening of its new warehouse. 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. With ambitious growth plans for 2025 and beyond, Polyhose needed to create additional warehousing space to accommodate a broader range of products and increase the depth of its UK stock holding. Marc Whibley, Managing Director at Polyhose UK, commented: “We were delighted to welcome guests to celebrate the opening of our new warehouse with our staff. It has been incredible to see our vision for the new space come to life, and we can’t wait to reap the benefits for our business and our customers.” Chris Butcher, Managing Director at the BFPA, added: “It was a pleasure to be invited to the official opening of the new Polyhose warehouse and to meet their hardworking team. The new building is fantastic and is an excellent example of the investment our members are making in the £1.5+ billion UK fluid power industry.” At the event, Martin Kingsbury, Director of Membership & Training at the BFPA, and Chris Butcher presented Polyhose UK with a certificate congratulating them on 40 years in business. The company was initially incorporated in 1985. Polyhose worked with Dorset manufacturer Mar-Key Group on the warehouse installation. Visiting the site, Dorset Chamber Chief Executive Ian Girling remarked: “Dorset has a vibrant and exciting business community. It is a pleasure to visit projects like this and see Chamber members working together to deliver economic growth.” With customers across the UK, Polyhose products are used in all kinds of fluid transfer applications, including hydraulic systems in manufacturing, construction, agriculture, automotive, marine, rescue equiment 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. Their culture of excellence means highly engineered fluid conveyance products that industries can trust to perform every time. Polyhose UK has been consistently accredited to ISO9001:2015 for sales and distribution, assembly and testing of thermoplastic, PTFE and rubber hoses and associated fittings and components for over 27 years. It has been a member of the Dorset Chamber for more than 30 years and is a member of the BFPA, the UK’s only trade body for the Hydraulic and Pneumatic Industries. Business expansion as Polyhose UK officially opens new warehouse facility Martin Kingsbury, BFPA, Marc Whibley, Polyhose UK & Chris Butcher, BFPA
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NEWS 10 HYDRAULICS & PNEUMATICS April/May 2025 www.hpmag.co.uk The Institution of Mechanical Engineers (IMechE) is continuing its partnership with Primary Engineer, building on a shared goal of expanding engineering education throughout the UK. This ongoing collaboration focuses on introducing young students to the world of engineering while providing teachers with the tools to effectively teach STEM subjects in their classrooms. This partnership directly supports IMechE’s Education & Skills objectives, creating a clear alignment between the two organisations in their commitment to improving engineering education. By working together, they aim to inspire, engage, and support a broad range of stakeholders, including students, teachers, and industry professionals, all while widening the pool of future engineers. The ultimate goal is to address the skills gap in the sector and encourage more young people to pursue careers in engineering. Primary Engineer has significantly expanded its reach over the past year, engaging over 117,000 students in the 2023-2024 academic year alone. This growth reflects the organisation’s efforts to bring engineering education to a wide variety of schools, from city centres to rural areas. By offering practical, handson engineering projects, Primary Engineer provides students with the chance to explore real-world applications of engineering concepts. The organisation has also trained over 2,000 teachers, ensuring that the delivery of engineering education is consistently high-quality and accessible. Industry involvement plays a central role in Primary Engineer’s approach. In the last academic year, 1,608 engineers and technology professionals volunteered to engage directly with students and teachers, offering valuable insights into the broad range of careers available in the engineering field. IMechE strongly supports this model, as it allows young people to see the practical relevance of engineering and gain a better understanding of the skills needed to succeed in the sector. The Leaders Award, one of Primary Engineer’s standout initiatives, encourages students to tackle real-world problems and develop engineering solutions. In 2023-2024, more than 75,000 students from across the UK participated in the competition, which provides an opportunity for students to receive recognition for their work. Each participant receives a certificate from an engineer, which not only acknowledges their effort but also reinforces the link between education and the professional world of engineering. Looking ahead, both IMechE and Primary Engineer are committed to continuing their work together to reach even more students across the UK. With a shared aim of addressing the engineering skills gap, the partnership is seen as a crucial way to equip the next generation with the knowledge and inspiration they need to pursue careers in engineering. Through this partnership, IMechE and Primary Engineer are helping to shape the future of engineering in the UK, ensuring that young people from all backgrounds are given the opportunity to explore the field and realise their potential as engineers. IMechE strengthens partnership with Primary Engineer to inspire the next generation of engineers On March 13, 2025, the British Pump Manufacturers Association (BPMA) returned for the third consecutive year to St George’s Park in Staffordshire, where it hosted the 2025 Pump Industry Awards presentation evening. Marking the 25th Anniversary of the prestigious awards, this year’s event was a resounding success, with a sold-out crowd of around 300 industry professionals gathering to celebrate excellence in pump manufacturing and distribution. The milestone anniversary saw a record number of submissions across the ten award categories, further highlighting the innovation and dedication within the sector. With entries reflecting the impressive breadth and diversity of the pump industry, the evening’s celebrations served as a powerful reminder of the value of in-person events, allowing professionals to reconnect, network, and honour achievements that are often hard to measure but essential to the sector’s ongoing success. Lee Tebbatt, Managing Director of Wilo UK and President of the BPMA, officially opened the evening with a warm welcome to the 2025 Awards Finalists. He emphasised their outstanding achievements, before turning to the BPMA’s work on noncompliant circulation pumps. Tebbatt also addressed the broader responsibility of the pump industry to address urgent global challenges, including water scarcity, energy shortages, and climate change—issues on which the sector’s innovations can have a profound impact. In keeping with the sporting theme that has characterised BPMA’s 25th Anniversary Awards recognise pump industry’s top innovators and winners
www.essentracomponents.co.uk MAKING IT EASIER 0345 528 0474 sales@essentracomponents.co.uk HYDRAULIC & PNEUMATIC PROTECTION At Essentra, we deliver a trusted range of hydraulic and pneumatic protection products designed to safeguard your critical applications. With UK-based manufacturing and a global production footprint, Essentra combines local agility with international reach. Our in-house engineering expertise and decades of industry knowledge also ensure we can meet custom requirements at scale – fast. Contact our local experts PROTECTION PLUGS HOSE PROTECTION PROTECTION CAPS CABLE MANAGEMENT CINCH STRAPS 65 YEAR S’ EXPERIENCE MANUFACTURING IN THE UK FREE SAMPLES FAST DESPATCH
NEWS 12 HYDRAULICS & PNEUMATICS April/May 2025 www.hpmag.co.uk previous editions of the awards, the guest speaker for the evening, Perry McCarthy, delighted the audience with tales from his remarkable career. Known for his ‘against the odds’ journey to Formula 1, McCarthy captivated guests with anecdotes from his time as the original Stig on BBC’s Top Gear. The evening’s mood was further elevated as McCarthy took part in presenting the main awards and also participated in a charity game of ‘Higher or Lower,’ which raised £1755 for WaterAid—the BPMA’s chosen charity for the event. Wayne Rose, BPMA’s Director and CEO, expressed his satisfaction with this year’s awards programme, noting the enthusiastic participation and the high calibre of entries: “It was another great night celebrating the hard work and achievements of the pump industry. The awards dinner provides the perfect opportunity to catch up with industry colleagues and make new connections in a relaxed and friendly environment.” He continued: “I was again impressed by the quality of entries, and I am so pleased to have this fantastic annual showcase as part of the BPMA’s support package for the pump sector.” The evening culminated with the announcement of the 2025 Pump Industry Awards winners. With sponsorship from some of the most respected names in the industry, the awards recognised the outstanding achievements of businesses and individuals whose work stood out in the year leading up to December 2024. The full list of winners includes: Product of the Year – Sponsored by DFA Media Group Winner: Salamander Pumps – AquaScan Project of the Year – Sponsored by World Pumps Winner: Selwood – Complex Overpump during STW Repair and Maintenance Works for Northumbrian Water Group Environmental Contribution of the Year – Sponsored by SPP Pumps Winner: Crest Pumps – Revolutionizing Data Center Sustainability with AVF-C Pump Technology Manufacturer of the Year – Sponsored by WEG UK Winner: SPP Pumps Distributor of the Year (less than £3m turnover) – Sponsored by Calpeda Winner: Deckpro Pumps Distributor of the Year (more than £3m turnover) – Sponsored by Caprari Winner: Tomlinson Hall Supplier of the Year – Sponsored by Wilo Winner: WEG UK Contribution to Skills & Training – Sponsored by Crest Pumps Winner: Tomlinson Hall / Middlesbrough College – Pump Centre of Excellence Rising Star Award – Sponsored by Innomotics Winner: Patrick Worth, Anglo Pumps Sustainable Contribution for a Better World – Sponsored by AESSEAL Winner: Wilo – Water Security and Optimisation Project Entries for the 2026 Pump Industry Awards will open in midJune, with a deadline for submissions set for November 28, 2025. The awards, free to enter and open to all companies within the pump sector, will once again celebrate the remarkable achievements of the industry. For more details and to submit entries, visit www.pumpindustryawards.com.
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NEWS 14 HYDRAULICS & PNEUMATICS April/May 2025 www.hpmag.co.uk IET responds to Spring Statement, emphasising innovation and skills for defence industry growth The Institution of Engineering and Technology (IET) has welcomed the UK Government’s commitment to boosting the nation’s defence industry in the Spring Statement, particularly the £400 million investment in the development and deployment of new technologies like quantum computing and artificial intelligence (AI). According to Stephanie Baxter, Head of Policy at the IET, this funding has significant potential to drive groundbreaking innovations in engineering and technology, not only advancing the UK’s defence capabilities but also benefiting the wider economy and society. Baxter acknowledged the government’s vision of making the UK a Defence Industrial Superpower, but she stressed that such ambitions would not be realised without a critical focus on the skills of the workforce. She explained: “However, we will not be able to become a secure, sustainable and resilient Defence Industrial Superpower without the highly skilled engineers and technologists who underpin the advanced manufacturing base. That is why it is critical that government also invests in the skills training and systems to ensure these new technologies are secure and resilient against vulnerabilities.” The IET’s statement underscores the need for government investment in skills training and systems to ensure that the Make UK’s Industrial Strategy Skills Commission has called for sweeping reforms to address the UK’s growing skills deficit, which is hindering economic and productivity growth. The Commission’s recommendations include the creation of a formal ‘Skills Covenant’ between government and industry to increase investment in workforce training and upskilling. Among its proposals, the Commission advocates for ringfencing the £800 million in unspent employer contributions to the Growth and Skills Levy and redirecting the £650 million raised annually from the Immigration Skills Charge solely to skills investment. These funds could train 40,000 new engineers, addressing the manufacturing skills gap that costs the UK economy £6 billion annually. The Commission also highlights the decline in vocational courses, particularly in engineering and manufacturing, due to financial pressures on education providers. To remedy this, it recommends increasing funding for key courses, such as the Level 3 engineering apprenticeship, and allowing levy funds to be used for investing in equipment and machinery. To further support upskilling, the Commission proposes a tax rebate for businesses investing in accredited training, along with a revamp of careers guidance in schools. It also calls for expanding the University Technical College (UTC) model to provide more technical training opportunities. Robert Halfon, Co-Chair of the Commission, emphasised the need for reform to support innovation in manufacturing and engineering, especially in new green technologies. He warned that failure to act could undermine the UK’s growth agenda. Make UK CEO Stephen Phipson echoed these concerns, criticising the current Apprenticeship Levy and urging immediate action to ensure proper funding for vital courses and recruitment of experienced trainers. The Commission’s message is clear: urgent action is needed to address the UK’s skills crisis and secure the future of its manufacturing sector. Make UK’s Industrial Strategy Skills Commission proposes sweeping reforms next generation of engineers are equipped to tackle the complexities of emerging technologies. With the increasing reliance on cutting-edge innovations in defence, Baxter highlighted the importance of ensuring these new technologies are secure, resilient, and protected against potential vulnerabilities. As the UK looks to strengthen its position as a leader in defence innovation, the IET’s call for a balanced investment in both technology and talent development is a reminder that the country’s ambitions must go hand-inhand with long-term strategies for skills development to maintain a competitive and secure edge.
discover more ASME B31.1-B31.3 UNI EN ISO 9001 2014/68/UE EN 13501-1:2007 Aluminium modular piping systems for the distribution of fluid energy. Systems for compressed air, vacuum, nitrogen, gas and technical fluids. Customised ergonomic solutions. Design, energy saving and pay-back services. HOLLOW BAR SYSTEM ALUMINIUM PIPING SYSTEM DROP COLUMN SYSTEM AIR & ELECTRIC TRACK SUPPLY MODULAR TROLLEY SYSTEM - PRESSURISED WORK BENCH FOR ASSEMBLY - PRESSURISED SWINGING ARM BRACKET - PRESSURISED ALUMINIUM MANIFOLD SYSTEM MULTIFLUID PIPING SYSTEM 25 BAR hbs dcs ats aps ams wba mts mps sab In 1988 Teseo Srl invented a market by developing and bringing to market worldwide innovative modular aluminium piping systems for compressed air and technical fluids distribution. Revolutionary systems, carefully designed and manufactured in Italy, designed to be quick to install, durable and efficient over time: all this with a view to economic, energy and environmental sustainability. Since then, Teseo has never stopped inventing and designing products and services tailored to each customer’s needs, also enhancing its range of solutions for the distribution of compressed air and technical fluids, in order to be a solid and reliable partner from the compressor room to the machine or workbench. With the experience and expertise that only the Company that invented the product can provide. ERGONOMIC CUSTOMISED SOLUTIONS TESEO SRL Via degli Oleandri, 1 - 25015 Desenzano d/G BRESCIA - ITALY - T. +39 030 9150411 100% RECYCLABLE ALUMINIUM LIGHTWEIGHT AND ROBUST QUICK AND EASY TO INSTALL PLUG & PLAY EASY TO ASSEMBLE AND DISASSEMBLE ZERO WASTE 100% LEAK-FREE ENERGY SAVING CONSULTING DESIGN REDUCED COSTS DURABLE AND RESISTANT HIGH TECH DESIGN Write to: sales@teseo.co.uk to find your nearest Teseo distributor in the UK! MADE IN ITALY 5/G20 4 - 5 JUNE | NEC - Birmingham
HYDRAULICS Ibiza is renowned for its beaches and stunning landscapes, which attract hundreds of thousands of visitors each year. The extra population creates huge volumes of wastewater that need to be treated to ensure the rivers and beaches remain in excellent condition. Challenging heights The most recent addition to the sewerage infrastructure on the island was an intermediate pumping station that needed to be located in the heart of a popular tourist area, but thanks to its design, it will not be noticed by all those enjoying the local hospitality. To avoid any unpleasant odours, the wastewater treatment plant is located away from the urban areas, but it is 120 meters above the pumping station, creating a design challenge as an intermediate pumping station was not an option in this case. Typical wastewater installations use gravity wherever possible to minimize the use of pumps, but they are essential in many situations. A network of pumping stations is used to transfer wastewater to the local treatment works, which are usually positioned close to a water course to accept the treated effluent. However, the situation in Ibiza is more challenging. In this case, the town’s winter population of 160’000 swells to around 450’000 in the summer, requiring a considerable increase in pumping capacity. The designers of the new pumping station also knew that, to achieve the head of 120 m, they would need to arrange several sets of two pumps in series. Proving capabilities While creating the basic layout, the designers also needed to source the pumps that would be installed in the station. However, the exact specifications required fine-tuning along with the control philosophy and the precise layout of the pipework. Sulzer’s expertise in water management and pump design made the manufacturer a clear favourite to support the project. Despite the unusual nature of this type of installation, Sulzer was able to successfully provide valuable know-how in similar installations in different countries. The basic design for the pumping station called for 12 pumps, 6 in a wet well with each one connected in series to its pair in the dry well. The outflow from the dry well is gathered in a common collector that is connected to a pressure vessel, which absorbs any pressure spikes, known as a “water hammer” effect, when pumps start and stop operating. This is especially important in high head and long pipe installations. Design expertise While the initial design was drafted, much of the details were incomplete, especially relating to the pipe diameters, pump connections and control principles. Sulzer was able to contribute extensive knowledge to define all the parameters and complete the design before construction started. In the meantime, since the pump specifications had been agreed, Sulzer set out to deliver the 12 XFP pumps in line with the build schedule, which was slightly unusual in that they would be assembled in position with the collection manifold before the building was erected around them. Those in the wet well were arranged vertically, while the pumps in the dry well were installed horizontally. All the pumps were equipped with special high-pressure mechanical seals to enable them to operate in both wet and dry locations. Sulzer also provided design expertise to the project by calculating the dimensions of the taper sections, which are crucial for minimizing vibration and cavitation. Equally important was the support Sulzer supplied for the control system, which Managing wastewater is best kept out of sight and away from local populations, but this is not always possible. In Ibiza, where huge numbers of visitors arrive in the summer, handling all extra wastewater poses a significant challenge. Sulzer was contracted to support the recent construction of a new pumping station providing both design expertise and the supply of 12 high-efficiency pumps. H&P reports. 16 HYDRAULICS & PNEUMATICS April/May 2025 www.hpmag.co.uk Efficient pumping supports wastewater management in Ibiza
www.hpmag.co.uk HYDRAULICS & PNEUMATICS April/May 2025 17 0114 349 0766 | info@plascompo.com | www.plascompo.com SPECIALISTS IN HOSE PROTECTION SPIRALS • HDPE • NYLON • PVC • FLAME RETARDENT • MSHA • EN 45545 • COLOURS • TWO COLOUR • FLAT PROFILE • DOMED PROFILE SLEEVING • POLYPROPYLENE • POLYESTER • POLYAMIDE • VELCRO FIXING • FIRE SLEEVE • PVC SLEEVE • POLYURETHANE SLEEVE • OVERBRAIDS • STAINLESS • GALVANISED All made in Europe & UK needed to carefully start and stop pairs of pumps as the inflow to the wet well increased. Efficient controls Operating pumps in series requires a higher level of control to ensure downstream assets operate efficiently and only when the preceding pumps are working. This can be achieved using timers, but this increases the risk of dry running of the top pumps, which must be avoided. Sulzer suggested a control system that uses pressure sensors to control the drywell pumps in conjunction with variable speed drives, which optimize efficiency and ensure output pressure is maintained. The system also coordinated the operation of the pump pairs to ensure inflow into the wet well was managed effectively. When the pumping station was commissioned, Sulzer provided support to the operator to ensure all the pumps were correctly set up. Since the project was completed, the pumps have been working without fault for more than a year, ensuring all the wastewater is effectively pumped to the wastewater treatment plant, which is also equipped with Sulzer pumps, mixers, diffusers, Scabas and HST compressors, where it is treated, without impacting the local population. Now, the additional pumping capacity will help to keep the White Isle pristine, even during the busiest holiday season. For further information please visit: www.sulzer.com
HYDRAULICS The assumption that maximum filtration efficiency always equates to better protection can be misleading. In practice, a highly efficient filter that captures very fine particles may also reach its dirtholding capacity much faster, triggering bypass conditions or requiring frequent replacement. On the other hand, a filter with a longer service life might allow more contaminants to circulate, increasing the risk of component wear over time. Understanding this balance is essential to selecting filters that suit the operational requirements and risk tolerance of a specific application. The efficiency curve Filtration efficiency is typically measured using the Beta ratio, which quantifies the filter’s ability to remove particles of a certain size. For example, a Beta(10) rating of 200 means the filter captures 99.5% of particles 10 microns or larger. While this might appear ideal, it can come at the cost of significantly increased pressure drop and reduced service life. A higher efficiency filter generally features tighter media, which restricts flow more than a lower efficiency equivalent. This increases the differential pressure across the element, especially as it loads with contamination. If the pressure drop exceeds the system’s design limits, it can result in the bypass valve opening, allowing unfiltered fluid to reenter the system. Ironically, a highly efficient filter may end up offering little to no protection if bypassing becomes frequent. Service life considerations Filter life is not defined by a set number of operating hours but by how long the filter can function effectively before reaching a critical pressure drop or becoming clogged. This life span is affected by fluid cleanliness targets, the volume of contamination present, system pressure, fluid viscosity, and the physical construction of the filter media. A longer-life filter is not necessarily one with lower efficiency. Some advanced filter media use multi-layered or depthloading construction to trap particles throughout the media, rather than just on the surface. These designs extend dirtholding capacity without severely compromising flow, although they may come at a higher cost. System operators should be wary of relying solely on published efficiency ratings or expected service intervals. Field conditions vary, and actual performance depends heavily on factors such as startstop frequency, fluid degradation, and ambient contamination sources. Application-riven decisions The trade-off between efficiency and life must be evaluated against the needs of the specific application. In high-pressure or precision systems—such as those found in aerospace, medical equipment, or injection moulding—high-efficiency filtration may be non-negotiable. The risk of particle-induced failure justifies more frequent filter changes and the associated downtime. In contrast, in systems with less critical tolerances or intermittent operation, slightly lower efficiency filters with longer life might be more appropriate. Mobile machinery, for instance, often faces variable contamination loads and benefits from filters with greater dirt-holding capacity and robust bypass mechanisms. Maintenance capabilities and monitoring tools also factor into the equation. Systems equipped with differential pressure sensors or condition monitoring can afford to use shorter-life, high-efficiency filters, as maintenance can be scheduled with accuracy. In less monitored environments, longer-life filters Hydraulic system reliability hinges on effective contamination control. Filters, as the frontline defence against wear-causing particles, play a pivotal role in maintaining system health. But the selection of a filter is rarely straightforward. The trade-off between filtration efficiency and filter life is often overlooked, yet it has direct consequences for system performance, maintenance intervals, and long-term operating costs. H&P reports. 18 HYDRAULICS & PNEUMATICS April/May 2025 www.hpmag.co.uk Balancing filtration efficiency and filter life in hydraulic systems
www.hpmag.co.uk HYDRAULICS & PNEUMATICS April/May 2025 23 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 reduce the risk of unexpected clogging and unplanned downtime. Monitoring and adjustment The best filtration strategy is rarely static. It should evolve with system age, usage patterns, and fluid condition. New systems may not require the same level of filtration as older ones, where wear particles and seal degradation increase contaminant levels. Similarly, systems operating in clean environments will experience different loading than those exposed to dust, moisture, or airborne debris. Routine fluid analysis provides insight into actual cleanliness levels and can highlight trends in filter performance. If filters are consistently reaching bypass well before their expected life, or if cleanliness targets are not being met despite regular replacement, it may indicate a mismatch between filter specification and system conditions. Cost implications There is a financial side to this trade-off that extends beyond the cost of the filters themselves. Downtime, fluid degradation, accelerated wear, and energy losses due to increased pressure drop all contribute to the total cost of ownership. Selecting an ultra-fine filter that requires frequent changes may not be cost-effective if it does not demonstrably extend component life or improve reliability. Conversely, selecting filters based purely on service life or price can be a false economy if it leads to higher rates of component failure, especially in systems with expensive or hard-to-replace parts. Balanced selection approach Achieving the right balance between filtration efficiency and filter life involves a clear understanding of system priorities: Define Cleanliness Targets: Refer to ISO 4406 or relevant OEM guidelines based on system sensitivity and operational demands. Assess Contamination Sources: Include internal wear particles and external ingress through breathers, seals, and maintenance activities. Consider Maintenance Practices: Evaluate how frequently filters can realistically be inspected or replaced. Select Appropriate Media: Work with filter manufacturers to identify filter construction that provides both the required efficiency and adequate dirtholding capacity for the application. Monitor and Adjust: Use differential pressure gauges, filter indicators, and oil analysis to assess real-world filter performance and adjust the specification as needed. The tension between filtration efficiency and filter life is not a problem to be solved once, but a balance to be managed continuously. By focusing on applicationspecific requirements and using datadriven decision-making, engineers and technicians can select filtration strategies that protect equipment without imposing unnecessary maintenance burdens. With the right approach, it is possible to achieve both system cleanliness and operational efficiency.
HYDRAULICS Micron Eagle Hydraulics has introduced a new solution designed to address a longstanding challenge in industrial maintenance: effective fluid monitoring. The Fluid-fitness Remote Online Guardian, or FROG, offers a shift from traditional methods of fluid condition monitoring, enabling real-time data analysis and proactive maintenance for industrial systems. In this context, ‘fluid’ refers to essential industrial liquids such as hydraulic fluids, lubricants and certain fuels, essential for the smooth and efficient running of machinery. FROG offers predictive intelligence and customisable alerts to monitor these fluids in real-time, enabling proactive asset management. By detecting contamination issues, FROG helps prevent costly downtime, improve operational efficiency and support sustainability, ultimately transforming maintenance practices and driving enhanced performance. It also helps reduce the need for frequent handling and disposal of fluids, contributing to a lower environmental impact by minimising waste and hazardous disposal requirements. It is the first product developed under Micron Eagle’s Fluid Fitness Technology (FFT) programme. This initiative is designed to transform how industries monitor and manage fluids, improving operational efficiency, extending the lifespan of equipment and refining maintenance practices. FFT also prioritises fostering collaboration and open dialogue within the industry, ensuring that solutions are responsive to both current needs and emerging challenges. Through this innovative approach, FFT aims to raise fluid performance standards while addressing complex industry demands with cuttingedge technology and expertise. Mark Burnett, Business Development Director at Micron Eagle Hydraulics, said: “FROG is a genuine industry gamechanger and has already been adopted by a major operator that immediately realised its benefits. “FROG acts as a radar for fluid fitness, communicating early-warning data to support the process of identifying potential equipment failures, while helping to optimise performance and asset integrity.” Micron Eagle Hydraulics has introduced the Fluid-fitness Remote Online Guardian (FROG), a real-time monitoring solution for industrial fluid systems. FROG enables proactive maintenance by detecting fluid issues early, improving efficiency, reducing downtime, and supporting sustainability through reduced fluid waste. Developed under the Fluid Fitness Technology initiative, FROG is transforming fluid management across various industries. H&P reports. 20 HYDRAULICS & PNEUMATICS April/May 2025 www.hpmag.co.uk Advancing fluid monitoring with real-time insights for proactive maintenance and efficiency
HYDRAULICS & PNEUMATICS April/May 2025 21 The solution offers a sleek and intuitive interface, allowing users to define precise set points for various elements such as contamination levels, temperature, relative humidity and pressure. Combined with the appropriate fluid conditioning unit, FROG forms a patented solution that has already secured contracts in the UK, Middle East and Africa. The development of this innovation was led by Henry Nagel, a director at Micron Eagle, based in Blackburn, Aberdeenshire. Cloud-based dashboard FROG’s cloud-based dashboard provides real-time data accessible to maintenance teams and management, whether offshore or onshore, via desktop or mobile device. It’s a preventative approach – one with visibility of system fluid health and notification of issues. Advanced analytics tools allow the identification of trends to facilitate proactive maintenance without disrupting existing workflows. Industries such as offshore oil and gas, manufacturing, transportation and power generation require robust fluid monitoring to ensure optimal equipment performance and reliability. In offshore oil and gas, monitoring lubricating and functional system fluids is crucial for safety and operational efficiency. Manufacturing sectors benefit from fluid monitoring in production machinery, hydraulic presses and assembly lines to minimise downtime and maintain precision. The transportation industry is increasingly reliant on effective fluid management to support sustainability goals. In power generation, maintaining the quality of www.hpmag.co.uk turbine and generator fluids is of paramount importance in the prevention of outages. The company says that fluid monitoring relies on periodic manual sampling and lab analysis - a timeconsuming process that does not capitalise on today’s digitisation approach. This traditional periodic sampling method can also pose potential issues: Elongated process: Sending samples to labs can take weeks, potentially causing sample degradation and delaying crucial maintenance decisions. Snapshot Data: Lab tests provide only periodic snapshots, missing ongoing changes in fluid conditions. Potential for Errors: Manual sampling can introduce contaminants, leading to inaccurate results. Aligned with today’s automated processes, FROG communicates ‘live’ insights into the condition of systems fluids, allowing for proactive maintenance and significant cost savings, reducing the potential for error. The company says FROG can help for several reasons: Proactive Maintenance: By enabling early detection of fluid issues, FROG’s real? time monitoring and communicating ability supports proactive decision-making and preventive maintenance. Cost-Efficiency: Live system communication allows the optimisation of equipment performance, extends asset lifespan and lowers maintenance costs. Environmental Impact: FROG’s data has the scope to reduce environmental impact by minimising fluid waste through precise monitoring and proactive maintenance. Data-Driven Decisions: Utilise advanced analytics and trend detection to improve maintenance decision-making, enhance overall efficiency and provide immediate notifications of condition changes. Technical Support: The innovation seamlessly integrates with existing systems, with support from the FROG team. Failing to properly monitor fluid systems can lead to significant financial consequences. The replacement and disposal of contaminated fluids not only carry high costs but also present environmental risks. Additionally, component failures caused by unfit or poorly maintained fluids can lead to costly downtime, resulting in lost production and further impacting profitability. FROG offers precision, putting clients in control. Sensors track contamination, humidity, temperature – and other information – transmitting data to a secure portal. This continuous stream of real-time data allows for swift anomaly detection and trend analysis, empowering teams to anticipate issues and plan ahead. It also provides a comprehensive solution for fluid management, offering a range of benefits designed to enhance operational efficiency and asset longevity. For more information about FROG, visit https://www.microneagle.com/fft/ https://www.microneagle.com/frog/
HYDRAULICS In industrial environments where flexible hose assemblies play a vital role in operations, effective hose management often doesn’t get the attention it deserves, until something goes wrong. Yet, hoses are critical assets that ensure the smooth transfer of liquids, gases, or solids across a wide range of industries, from petrochemicals to food processing and offshore energy. Poor hose management can result in equipment failure, costly downtime, and serious safety incidents. This is why robust Hose Asset Management is no longer just a value-add; it’s an operational necessity. Hoses, by their very nature, are subject to wear and degradation over time. Regular handling, exposure to harsh chemicals, temperature extremes, and mechanical stress all contribute to their eventual deterioration. A seemingly minor fault, such as a small abrasion or a degraded coupling, can rapidly escalate into a catastrophic failure. The risks are well documented: unplanned shutdowns, environmental spills, worker injuries, and regulatory non-compliance. Yet, many organisations still rely on ad-hoc inspection methods or assume hoses will remain safe and functional until failure makes itself known. Proactive Hose Asset Management addresses these risks head-on The benefits of a proactive approach A structured Hose Asset Management System brings several benefits. It ensures hoses are correctly specified, installed, inspected, tested, and tracked throughout their lifecycle. This reduces the likelihood of failure, extends the life of hose assemblies, and optimises operational efficiency. When assets are logged and monitored systematically, it allows for predictive maintenance rather than reactive repair. This proactive approach helps to minimise costly unplanned downtime and increases the reliability of the entire system. Data-driven maintenance and tracking At its core, effective hose management is about data. Gathering it, analysing it, and acting on it. Modern Hose Management Systems often include tagging technologies such as RFID or barcodes, enabling quick identification of hoses and instant access to their service history. Maintenance teams can quickly determine when a hose was last tested, whether it’s due for inspection, and its performance record over time. This level of visibility not only enhances safety but also supports compliance with industry standards such as BS EN ISO 8331 and HSE guidelines. Enhancing compliance and reputation For industries operating in high-risk environments, such as offshore oil and gas, pharmaceuticals, and chemical manufacturing, hose management is also about reputational risk. A well-documented system demonstrates commitment to safety, environmental responsibility, and best practices. These are qualities that are increasingly valued by stakeholders, regulators, and insurers alike. Supporting sustainability goals The move towards more sustainable operations further highlights the importance of hose management. Wellmaintained hoses operate more efficiently and are less prone to leaks, reducing waste and the risk of environmental contamination. Furthermore, extending hose life through proper care and monitoring reduces the need for premature replacements, contributing to sustainability goals. A critical investment in safety and efficiency Ultimately, Hose Asset Management is about taking control of a critical aspect of industrial operations. It’s a system that improves safety, ensures compliance, extends asset life, and reduces costs. For organisations serious about maintaining operational integrity and protecting both people and the environment, investing time and resources into hose management isn’t optional. It’s essential. David Wright, General Manager at Buckley Industrial, explains why effective Hose Asset Management is essential in industrial operations. By proactively managing hose assemblies, companies can prevent costly failures, enhance safety, improve efficiency, and support sustainability efforts. A robust system ensures reliability, compliance, and extends asset life. 22 HYDRAULICS & PNEUMATICS April/May 2025 www.hpmag.co.uk The critical role of hose asset management in industrial safety and efficiency
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