www.hpmag.co.uk JUNE 2025 HYDRAULICS & PNEUMATICS VOL. 30 No. 4 JUNE 2025 p38 p34 Enhancing manufacturing efficiency with electropneumatic applications Ensuring reliability and efficiency through comprehensive compressor assessments Why industrial facilities are going digital to tackle unplanned downtime p28 Bridging the gap in UK manufacturing through smart integration
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Spending Review receives cautious welcome EDITOR’S COMMENT www.hpmag.co.uk HYDRAULICS & PNEUMATICS June 2025 3 The Spending Review may offer positive signals, but it’s what comes next that will matter most. ‘ ’ In the wake of the Government’s latest Spending Review, manufacturers find themselves in familiar territory: cautiously optimistic, yet acutely aware that rhetoric and headlines are no substitute for follow-through. The review, unveiled against a backdrop of tight public finances and economic uncertainty, has been described by Make UK Chief Executive Stephen Phipson as a “delicate balancing act.” That sentiment captures the mood across industry—one of measured approval for targeted investments, tempered by an awareness of the deeper structural issues still awaiting resolution. There is justified welcome for increased spending on defence, science, and technology, alongside local transport investment beyond the South East. These are areas where manufacturing has a strong regional footprint, and the potential impact on local growth and productivity is significant. Yet, the absence of a fully articulated industrial strategy leaves a conspicuous gap. Manufacturers have long called for a coordinated, properly funded roadmap to secure the sector’s future—especially as it grapples with persistently high energy costs and a chronic skills shortage. As Phipson rightly points out, “These are not marginal issues.” Addressing them isn’t just desirable—it’s essential. Compounding these domestic concerns are growing international uncertainties. With recent geopolitical events reshaping global supply chains, trade dynamics, and defence priorities, there is every chance that this Spending Review will require significant re-evaluation in the coming months. The assumptions behind today’s allocations may not hold in tomorrow’s reality. The Spending Review may offer positive signals, but it’s what comes next that will matter most. Turning ambition into actionable policy will be the real test of the Government’s commitment to UK industry. Without it, manufacturers risk being left navigating the same structural headwinds—with fewer tools to compete. The question now is whether this review marks the start of a genuine industrial renaissance— or yet another missed opportunity. Aaron Blutstein Editor
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www.hpmag.co.uk HYDRAULICS & PNEUMATICS June 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. 24 34 6 NEWS 16 HYDRAULICS Technicians responsible for airside operations at one of Germany’s leading airports have turned to Gates following a series of competitor hydraulic hose failures in passenger airbridges, leaving them unable to load or disembark passengers and crew. H&P reports. 24 PNEUMATICS 28 KNOWLEDGE BASE 33 BFPA Hydraulics & Pneumatics’ issue-by-issue briefing on current activities and views involving the British Fluid Power Association. 34 APPLICATIONS Electro-pneumatic systems play a crucial role in modern manufacturing, blending electrical and pneumatic technologies for enhanced automation. However, challenges like energy inefficiency, system complexity, and operational reliability persist. H&P explores these issues and offers practical, solutions driven insights to optimise performance and ensure long-term efficiency in manufacturing environments. 36 INTEGRATED SYSTEMS 38 COMPRESSED AIR, VACUUM, AND GENERATORS Compressors lie at the heart of countless businesses across countless industries, and those businesses’ success depends on their equipment performing reliably, efficiently and sustainably. When this isn’t the case, they need easy and fast access to engineering excellence to assess and help them improve their compressors. H&P reports. 41 BCAS Our regular news and events update on the British Compressed Air Society. 42 NEW FACES 44 SPECIAL REPORTS 47 PRODUCTS & SERVICES DIRECTORY 38 Subscribe for your FREE copy now
NEWS 6 HYDRAULICS & PNEUMATICS June 2025 www.hpmag.co.uk UK manufacturers reassess U.S as export market amid tariff concerns The United States has dropped out of the top three global growth markets for UK manufacturers for the first time, according to the latest Manufacturing Outlook survey by Make UK and BDO. This shift reflects growing unease within the sector, driven by increased trade barriers, geopolitical uncertainty, and weakening demand from across the Atlantic. The Q2 2025 survey reveals that UK manufacturers now place greater emphasis on Asia/Oceania and the Middle East when targeting export growth, marking a historic change in sentiment. For decades, the US had consistently ranked as a top destination— second only to the EU—but now sits in fourth place. The fall in favour comes amid a significant trade decline, with official figures showing a £2 billion drop in exports to the US in April alone, the sharpest monthly fall since records began in 1997. Concerns about the impact of tariffs are widespread. A separate Make UK survey found that six in ten manufacturers expect US-bound exports to be affected, while nearly two-thirds anticipate broader negative consequences for their businesses. Around 30% of companies are reviewing their supply chains, considering alternative sourcing strategies, yet only 4% say they are looking into setting up operations in the US—signalling a clear drop in confidence. Meanwhile, in the US, optimism among American manufacturers has also declined. According to the National Association of Manufacturers, sentiment is at its lowest since the pandemic, with 77% of companies citing trade uncertainty as their main concern. Despite these challenges, UK manufacturing output showed signs of recovery in the second quarter. Output bounced back to +9% from -1% in Q1, while export orders improved from +1% to +7%. Export strength helped cushion the impact of continued domestic weakness, where order balances remained negative at -1%, though this was still an improvement from -7% in the previous quarter. Projections for Q3 are tentatively optimistic, with output expected to rise to +11% and total orders to +13%. Export orders are forecast to climb to a balance of +22%, exceeding long-term averages. However, the positive momentum in output is not mirrored in investment activity. Capital spending intentions have been falling sharply since late 2024, and in Q2 dropped to just +2%, down from +5% in Q1 and +10% in Q4 last year. If this downward trend continues, Make UK warns that investment could turn negative in the second half of 2025, posing a threat to future growth and innovation in the sector. Compounding these concerns, growth forecasts for the manufacturing sector have been revised downward. After a flat year in 2024, the sector is now expected to shrink by 0.2% in 2025, with the projection for 2026 cut drastically from +1% to -0.5%. This suggests a prolonged period of stagnation or contraction, adding urgency to calls for government intervention. Seamus Nevin, Chief Economist at Make UK, said the figures highlight the severity of the challenges facing manufacturers: “While at first glance the headline numbers may not look too bad, manufacturers are facing a gathering storm of huge uncertainty in one of their major markets, a skills crisis and eyewatering energy costs which are providing a harsh reality for many. In response, it’s absolutely essential that the forthcoming industrial strategy takes bold measures to bring down the cost of energy and takes equally radical action to ensure companies can access the people they need to take advantage of a more competitive landscape. If these two issues are not addressed, then we will face the serious prospect of the UK accelerating into de-industrialisation.” His comments were echoed by Richard Austin, Head of Manufacturing at BDO, who noted: “This quarter’s results are a testament to the increasingly challenging landscape our British manufacturers are operating in. The forecasted decline in growth is concerning and the delayed industrial strategy won’t help to assuage uncertainty in the sector. That said, there remain pockets of positivity. Growing output levels are proof of manufacturers’ resilience and last month’s trade deals should remove barriers as UK companies seek new trading partners and opportunities for growth. As always, they need urgent clarity and targeted investment from the government if this recovery is to continue into next quarter.” While there are glimmers of strength in near-term output and export performance, the overall picture remains fragile. With the US retreating as a reliable export partner and investment intentions weakening, the sector’s future will increasingly depend on swift and decisive policy action to address structural challenges—particularly energy costs and workforce development. Without such intervention, the UK risks sliding further down the path toward de-industrialisation.
NEWS 8 HYDRAULICS & PNEUMATICS June 2025 www.hpmag.co.uk UK emerges as Europe’s digital manufacturing frontrunner powered by AI and workforce transformation Global research report from Rockwell Automation reveals how UK manufacturers are leveraging artificial intelligence to enhance workforce capabilities and drive operational resilience. Rockwell Automation, the world’s largest company dedicated to industrial automation and digital transformation, has unveiled the UK findings of its 10th annual State of Smart Manufacturing Report. The research reveals that the United Kingdom is setting the pace in Europe, with manufacturers rapidly adopting artificial intelligence (AI), investing in workforce up-skilling, and prioritising cybersecurity as a strategic foundation for growth. The study, based on feedback from more than 1500 manufacturing leaders globally, highlights the UK’s striking progress in digital transformation. With 53% of UK manufacturers already implementing machine learning or AI on the factory floor, and an impressive 98% either using or planning to implement generative AI, the country is leading Europe in applied artificial intelligence. “AI is no longer just an emerging trend for UK manufacturers, it has become the driving force behind their transformation,” said Phil Hadfield, managing director at Rockwell Automation. “By combining a human-centric workforce strategy with deliberate digital investment, UK firms are not only embracing innovation but also achieving tangible performance improvements that position them as leaders in the global manufacturing landscape.” AI and generative AI are being deployed in quality control, cybersecurity, training content, and compliance reporting. Already, 15% of UK firms say GenAI delivered the highest ROI of any technology in the past year. Rather than replacing workers, UK manufacturers are using AI to enhance roles and address labour shortages. Thirty-eight percent of UK companies plan to upskill existing talent, up from 30% last year and well ahead of the European average of 30%. Cybersecurity has emerged as a foundational priority. With 97% of UK firms already investing or planning to invest in cyber platforms, and 21% citing it as their top ROI driver, businesses are building secure infrastructure before expanding digital services. Thirty-two percent now see cybersecurity as a top external risk, up from 28% last year. Meanwhile, digital twin adoption has jumped from 21% to 37% in just 12 months, with the UK reporting the highest planned adoption rate in Europe. Sustainability strategies also continue to mature, with 89% of manufacturers now operating under formal ESG policies, and 56% citing efficiency, not compliance, as the main driver. To view the full findings of the State of Smart Manufacturing Report please visit: https://bit.ly/3FQ3EdW Smart Manufacturing Week 2025 highlighted innovation, talent and technology Smart Manufacturing Week 2025 returned to the NEC Birmingham on 4–5 June. Bringing together Smart Factory Expo, Design & Engineering Expo, Drives & Controls, and Maintec—alongside specialist zones for Fluid Power & Systems and Air-Tech—the event offered wide-ranging insight into the technologies and trends shaping modern industry. More than just a showcase of products and services, the event was defined by its ambition to push the boundaries of what a manufacturing exhibition can deliver. With a focus on rich technical content, forward-looking innovation, and the sector’s most pressing priorities, Smart Manufacturing Week offered a comprehensive platform for learning, collaboration and inspiration. Live technology demonstrations were at the heart of the event. The Technology Showcase Arena featured working examples of robotics, artificial intelligence, digital twins, and connected industrial devices. One of the standout attractions was T-1-FNY, an eight-foot-tall, 300kilogram robot built from reclaimed parts. Originally designed for fictional destruction, the robot now performs domestic tasks, demonstrating object recognition and adaptive automation with surprising dexterity and a touch of personality. Elsewhere, Fracture Reality’s JoinXR platform was demonstrated in a series of exclusive VIP sessions. The technology, which enhances design workflows, technical training and team collaboration, offered visitors a glimpse into how extended reality is being used to streamline complex industrial projects and reduce error rates. For those looking towards the future of industrial innovation, Innovation Alley provided a compelling mix of early-stage companies and university spinouts. These participants, many of them actively shaping the next generation of industrial tools and systems, added a valuable
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NEWS 10 HYDRAULICS & PNEUMATICS June 2025 www.hpmag.co.uk entrepreneurial edge to the event. Smart Manufacturing Week also placed significant emphasis on the workforce of tomorrow. The Manufacturers and Engineers of the Future programme provided school and college students with hands-on workshops, practical demonstrations and the opportunity to engage directly with professionals in the field. The aim was to move beyond raising awareness and create tangible experiences that could inspire long-term interest in the sector. The speaker programme spanned seven dedicated theatres and brought together senior figures from leading companies including BMW, Airbus and Mars. Discussions ranged from the scalable application of artificial intelligence and the adoption of Industrial Internet of Things (IIoT) technologies, to emerging strategies for strengthening supply chain resilience. Adding a lighter touch, the popular Guitar Legends contest returned, inviting visitors to display their musical talents. Winners each day were awarded custom 3D-printed guitars, combining creativity with engineering flair in a way that underscored the event’s spirit of innovation and playfulness. Flowtech and SMC join forces to help supply UK industry A new joint venture has been announced to make it easier for UK industry to source tried and trusted fluid control solutions. Flowtech Fluidpower plc – the largest supplier of fluid power products, systems and solutions in the UK, Ireland and Benelux – has become the first UK wholesale distributor for SMC Corporation (UK) Limited, the UK and global market leader in fluid control and automation technologies. The agreement means a wide selection of parts from SMC’s standard selection will become available to order and shipped from Flowtech’s headquarters and Global Fulfilment Centre in Skelmersdale. The partnership was announced as Mike England, Group CEO of Flowtech, visited SMC’s UK manufacturing, logistics and administration facility in Milton Keynes to meet the new General Manager of SMC in the UK, Nick Pittwood. Flowtech customers benefit from access to over 600 staff, experienced in design and engineering across a wide variety of industry sectors who can provide technical advice, as well as aftermarket service and support with next day delivery of SMC stocked products. SMC is the UK market leader, providing its customers with a constantly evolving range of fluid control and automation solutions to serve OEMs as well as end users. The organisation offers a standard product range of more than 12,000 items with 700,000 variants, many of which will be available from Flowtech. Nick Pittwood, General Manager of SMC in the UK, commented: “Customers of both organisations will benefit from Flowtech’s country-wide coverage with next day delivery, backed up with the vast amount of experience and sector specialisms that both SMC and Flowtech provide. This partnership between two market leaders makes perfect sense, to add a powerful channel for those customers to be able to secure the right solution for their needs, with the minimum lead time, and I’m delighted that Flowtech is joining our sales partner family.” Mike England, CEO of Flowtech, added: “We are delighted to announce this partnership today. By joining forces with SMC, we’re combining our best-inclass distribution expertise with world class product and engineering innovation, ensuring easier access to high performance solutions, exactly when and where they’re needed. Together, we’re setting a new standard in service and supply for UK industry.”
NEWS 12 HYDRAULICS & PNEUMATICS June 2025 www.hpmag.co.uk Leading US manufacturer Todd Technologies Inc (TTI), headquartered in Colorado, is aiming to strengthen its presence in the UK and Ireland by developing new strategic partnerships with distributors in both markets. While TTI currently serves many European customers via its new manufacturing plant in Morsbach, Germany—where it produces PowerBreather desiccant breathers, adapter kits, and PowerGuard filter media upgrades—the company now plans to expand its operations in the UK and Ireland. This expansion involves establishing a network of distributors to sell and maintain TTI products sourced from the Morsbach facility. To spearhead this growth, TTI has appointed Wayne Hubball, former Technical Director at the ATEX Particle Counting Company, as UK and Ireland Product Manager. Derek Kula, TTI’s Vice President of Business Development, recently visited the UK to better understand the market and meet potential partners. “We already had a good idea of how the market operates over here,” said Kula, “but it’s been great to learn even more and experience just how committed these companies are to providing exceptional customer service.” TTI is recognised as a prominent leader in sectors including hydraulic equipment, power generation, steel, and oil & gas. Its product portfolio includes PowerBreather desiccant breathers and PowerGuard filter elements and housings, designed to reduce maintenance costs and minimise environmental impact. Independent head-to-head trials have demonstrated that TTI PowerBreathers typically last around 20% longer than those from leading competitors, resulting in reduced annual breather expenditure through savings on both units and freight. “We’re very confident of our products and we won’t be beaten technically or on price,” Kula added. “As we like to say in the US, we’ll take the Pepsi challenge with any other manufacturer – on like-for-like products – and always save the customer money. That’s the formula we’ll be rolling out in the UK and Ireland.” During his visit, Kula met with several prospective partners, including Fleury Engineering in County Cork, specialists in bespoke industrial fuel systems and mission-critical equipment solutions. Fleury Engineering serves a broad range of sectors—from turbines and data centres to airports—providing preventative maintenance and fuel and oil-related issue resolution to ensure asset reliability. Kula also visited OMS LubriTek, a leading supplier to the plastics industry, and Trident Hydraulics, a developer of hydraulic systems. He emphasised the company’s intent to forge additional partnerships with distributors whose portfolios align with TTI’s offerings. “The UK and Ireland are strategic growth markets for us over the next three years,” Kula said. “We have made significant investment in setting up our Morsbach operations. We’ve appointed a new product manager to manage distribution growth and are already securing new business through several OEMs that we’re working with. “We want to make sure we get this right. These are exciting times and everyone at TTI is committed to ensuring our British and Irish operations hit the ground running. We’d love to hear from anyone who thinks they might fit the bill!” With this expansion, TTI looks set to deepen its foothold in the UK and Irish markets, leveraging proven products and new partnerships to drive growth across key industrial sectors. Todd Technologies announces growth plans for UK and Irish markets
Award Programme Partners The BPMA’s annual Pump Industry Awards programme has been recognising and rewarding the achievements of pump businesses, large and small for over two decades. Throughout that time it has become one of the leading events to serve the industrial and commercial arena. So, if you or your company have a pump related success to shout about, these awards provide the perfect platform. The gala presentation dinner caps off the awards programme in style, providing excellent networking opportunities, great food and superb entertainment. It’s your chance to celebrate with colleagues, interact with peers, entertain customers and be part of the pump industry’s biggest and best celebration. Manufacturing and distribution prowess, product development and application, environmental consideration, skills development and customer support will all be acknowledged through this wide reaching awards programme. So why not consider which of your engineering successes are deserving of industry wide recognition, and be sure to join us at our wonderful venue - the home of English football - on Thursday 19th March 2026. PUMP INDUSTRY AWARDS 2026 Recognising and Rewarding Excellence Lee Tebbatt, BPMA President, says of the Pump Industry Awards,“The pump industry has long been a hotbed of innovation, with manufacturers striving for engineering excellence to deliver greater operational performance and improved efficiencies to its broad customer base. The industry landscape is changing and as a collective, we’re moving the dial on important issues such as water scarcity, energy shortage and climate change, we’re driving sustainability across our supply chains and we’re sharing best practice among our members. This BPMA backed awards programme brings the pump industry together in celebration of this drive for industry excellence. Event Calendar Nominations Open: 1st July 2025 Nominations Close: 28th November 2025 Judging Session: Mid December 2025 Voting: 12th – 16th January 2026 Winners Announced: 19th March 2026 www.pumpindustryawards.com Organised by on behalf of Venue: Hilton at St George’s Park, Burton upon Trent Date: Thursday 19th March 2026 NOMINATIONS OPEN 1ST JULY Will you be crowned a winner in 2026?
NEWS 14 HYDRAULICS & PNEUMATICS June 2025 www.hpmag.co.uk Fluid Filtration launches in the UK May 2025 saw the launch of Fluid Filtration which will exclusively sell Ikron filters in the UK. Founded by industry veteran Sophie Fisher, the company reflects her commitment to integrity, quality, and customer service. After a distinguished 35-year career with a single organisation, redundancy in March 2024 prompted Sophie Fisher to reassess her professional direction and reconnect with her passion for the fluid power sector, where she has amassed 40 years of experience. Over the past year, she recognised that re-entering the industry required a fresh approach — one grounded in accountability, integrity, and alignment between her personal values and those of the businesses she represents and partners with. “It’s about more than just business; it’s about integrity, accountability, and a commitment to quality and customer service,” she explained. “Working with partners who share those principles is essential.” Her search led to a partnership with Ikron Srl, an Italian manufacturer of hydraulic filters and a subsidiary of the Casappa Group — a global leader in pumps, motors, filters, and hydraulic systems based in Parma, Italy. A visit to Ikron’s facility confirmed their shared commitment to honesty, integrity, quality, and customer service. “Ikron is the partner I’ve been looking for,” she said. “Together, we will advance within the UK market with passion and dedication.” To mark its launch, Fluid Filtration is offering free delivery for the first 20 customers placing orders for delivery by December 2025. For further information, please visit: https://www.fluidfiltration.co.uk/ NHL launches refreshed brand identity to reflect growth and heritage NHL, formerly known as Northern Hydraulics, has announced the launch of its refreshed brand identity. Going forward, the company will operate under the streamlined name “NHL”. This rebrand includes a modernised logo and visual identity that reflects NHL’s strong position in the hydraulic cylinder industry and its ambitions for future growth. While the name may be shorter, the commitment to quality, partnership, and performance remains stronger than ever. The new identity embodies NHL’s legacy of over 40 years while representing its forward-thinking approach and commitment to excellence. Barry Morris, CEO, NHL commented: “This transformation isn’t just about a new logo, it’s about aligning our visual identity with who we are today and where we’re going. As we continue to serve customers across four continents, it’s important that our brand reflects the strength, reliability, and innovation that NHL stands for.” With more than 400,000 cylinders produced in the last three years and a team of 90 skilled experts, NHL is trusted by customers across four continents to deliver high-quality, dependable hydraulic cylinders. The company’s in-house design team, advanced robotic machinery, and stringent testing protocols ensure every cylinder performs flawlessly in even the most demanding environments. NHL delivers high-performance hydraulic cylinders tailored for demanding industries from construction and agriculture to aviation and waste management. With end-to-end capabilities including design, machining, welding, testing, and stock management, NHL ensures every project is delivered with precision, quality, and reliability. The new NHL logo features a 3D cylinder transforming into a forwardfacing arrow, representing precision, momentum, and engineered performance. It captures both NHL’s proud legacy and its dynamic vision for the future. For over four decades, NHL has built a reputation for delivering reliable, highperformance hydraulic solutions. With this refreshed identity, the company is staying true to its roots while embracing new opportunities to support customers around the world. Seamus Morris, Founder and Barry Morris, CEO
Call for nominations now open... The AEMT is once again looking to recognise and reward the people, companies, projects and services that play a crucial role in ensuring our food production, utilities, manufacturing processes, transportation and other essential services are maintained and secured. Produced by and operated by The Association of Electrical & Mechanical Trades 2025 Partners: AWARDS Online Entry at: www.aemtawards.com
HYDRAULICS The airport is now using Gates MegaSys hoses with a MegaTuff cover to replace failed competitor hoses, which have been prematurely breaking down. Handling 60 million passengers and over 430,000 aircraft movements annually across three terminals, the airport can’t afford the operational disruption caused by these failures. Hydraulic experts and Gates partner, Form-Plast GmbH, is conducting the replacement work, which includes removing the defective hose assemblies from the airbridge hydraulic system and performing a complete overhaul. Form-Plast’s managing director, Andreas Held, noted the original hoses supplied with the airbridges were not durable enough to withstand typical operating conditions, which often include prolonged immersion in oil. Inspection revealed pinholes, cracks, and significant wear, rendering the airbridges out of service and disrupting airport operations. Each overhaul requires between six and 15 hose assemblies, specific couplings, and careful routing to reduce stress under operating conditions. This year alone, Form-Plast has replaced 24 airbridges. Reflecting on the project, Andreas Held commented: “The airport operators were concerned about the unexpected, premature failure of the original hoses before their six-year replacement schedule. “However, we have successfully allayed those fears with Gates hoses. Records from a previous Gates hose installation in 2018 proved that Gates hoses could perform reliably over time in this environment.” Held added: “When a hydraulic failure occurs on an airbridge, the impact on operations is significant, leading to passenger delays and, more critically, potential damage to the aircraft. An airbridge unable to maintain the correct height during boarding or disembarking risks damaging the fuselage, particularly around the aircraft door.” Gates says its MegaTuff hoses are exceptionally resistant to abrasion, oil, ozone, and UV exposure, due to the material science behind the specifically designed cover compound as well as the process engineering to ensure the cover remains intact and does not peel under Technicians responsible for airside operations at one of Germany’s leading airports have turned to Gates following a series of competitor hydraulic hose failures in passenger airbridges, leaving them unable to load or disembark passengers and crew. H&P reports. 16 HYDRAULICS & PNEUMATICS June 2025 www.hpmag.co.uk Hydraulic hose upgrade boosts airbridge reliability at major German airport
www.hpmag.co.uk HYDRAULICS & PNEUMATICS April/May 2025 17 0114 349 0766 • info@plascompo.com • www.plascompo.com ECO RANGE OF PROTECTIVE CAPS & PLUGS Made entirely from second-life plastic Available now… demanding conditions. Importantly, they also maintain their flexibility and minimum bend radius, which simplifies installation and enhances durability. Seamless port-to-port solution The installations, according to Gates, have demonstrated impressive performance with no leaks or defects, a result of Gates’ extensive research and development to create a seamless portto-port solution. The hose and coupling combinations are designed to work seamlessly, offering trouble-free service throughout its working life, as FormPlast’s experience confirms. Held concluded: “By using Gates MegaSys MegaTuff hose assemblies, we have resolved these unexpected issues, eliminating airbridge failures and ensuring that they remain operational for the sixyear window, keeping operations running and reducing the airport operator’s maintenance costs in the long term.”
HYDRAULICS Hydraulic systems have always been synonymous with raw power. Built to lift, press, and drive heavy loads with remarkable force, they thrive where electric motors often reach their limits. At the heart of these powerful machines is the hydraulic motor—a robust piece of engineering that transforms pressurised fluid into mechanical motion. While electric motors often take the spotlight in conversations about Industry 4.0 and smart manufacturing, hydraulic motors have been evolving steadily, becoming more efficient, intelligent, and crucial to modern industry. Hydraulic motors are fundamentally different from electric ones. Rather than relying on electrical currents, they are driven by fluid power—high-pressure oil or water that flows through the system, delivering consistent and powerful torque. This makes them ideal for applications requiring substantial force at low speeds, such as winches, conveyor drives, and heavy lifting equipment. Unlike electric motors, hydraulic variants can withstand shock loads and maintain torque even when stalled, making them indispensable in demanding environments like construction sites, offshore drilling platforms, and largescale manufacturing plants. Digital monitoring One of the most significant developments in hydraulic motors is their increasing compatibility with digital monitoring and control systems. As Industry 4.0 continues to shape the landscape of manufacturing, hydraulic technology is not being left behind. Modern hydraulic motors are often equipped with sensors that provide real-time data on temperature, pressure, and rotational speed. This information can be fed back into centralised control systems, allowing for predictive maintenance and more efficient operation. Potential issues can be identified and rectified before they cause costly downtime, aligning hydraulic technology with the smart factories of the future. Energy efficiency has also become a critical focus. Traditional hydraulic systems were often seen as energyintensive, with substantial losses during fluid transmission. Advances in motor design, such as variable displacement technology and load-sensing systems, have dramatically improved their efficiency. Variable displacement allows the motor to adjust its fluid intake based on demand, reducing unnecessary energy consumption. Load-sensing, on the other hand, enables the system to detect the precise amount of force required for a task, further optimising power usage. These technologies are not only cutting costs but also supporting sustainability initiatives by reducing waste and energy consumption. Harsh and hazardous environments Another area where hydraulic motors excel is in harsh and hazardous environments. Electric motors, while efficient, often struggle in conditions that involve high levels of dust, moisture, or risk of explosion. Hydraulic systems, with their robust sealed designs, can operate reliably in such conditions. Offshore rigs, mining operations, and heavy industrial settings benefit from hydraulic technology that is not only resilient but also easy to maintain. In scenarios where electric sparks pose a risk, hydraulics provide a safe alternative without compromising on power or reliability. The adaptability of hydraulic motors is also contributing to their sustained relevance. Modern designs are increasingly modular, allowing for straightforward integration into existing systems. This modularity means that upgrades and replacements can be performed with minimal disruption, extending the lifespan of equipment and reducing capital expenditure. As manufacturers strive for more flexible and responsive production lines, hydraulic motors are proving that they are more than capable of meeting these demands. As the manufacturing landscape continues to embrace the principles of Industry 4.0, hydraulic motors are finding their place within the digital ecosystem. Far from being overshadowed by electric innovations, they are evolving to meet modern demands—quieter, more efficient, and more connected than ever before. The world of fluid power is not fading into the background; it is transforming, ready to power the next generation of industry with the same reliability and force that has defined it for decades. 18 HYDRAULICS & PNEUMATICS June 2025 www.hpmag.co.uk The crucial role of hydraulic motors in industry Hydraulic motors have long been the backbone of heavy industry, delivering unmatched power and resilience. Now, with advances in efficiency and digital integration, they are stepping confidently into the era of Industry 4.0—proving that fluid power remains essential in modern manufacturing’s push for smarter, more adaptable production systems. H&P reports.
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HYDRAULICS Hydraulic systems don’t often fail suddenly. Most problems build up slowly, and fluid contamination is usually at the centre of it. It doesn’t get much attention because it isn’t obvious. There’s no dramatic breakage. But it’s the most common reason hydraulic power packs become unreliable, inefficient, or need early replacement. Contamination tends to be treated as background noise. It’s understood in theory but rarely prioritised in day-to-day maintenance. It enters power packs in quiet, routine ways — from filling up with oil that’s been stored in an open container, or using a funnel that wasn’t properly cleaned, or simply through a worn breather letting in moisture and dust. Once inside, it moves with the oil through the pump, control valves, and any downstream circuits, slowly wearing down parts that were designed to run clean. Because hydraulic power packs are usually seen as self-contained and reliable, there’s often an assumption that if it’s running, it must be fine. But these units operate on tight tolerances. Even small particles — metal from internal wear, rubber from seals, dust from the environment — can cause lasting damage over time. They scratch surfaces, block ports, and disrupt valve performance. If water enters the reservoir, corrosion and fluid breakdown soon follow. In compact power packs where cooling is limited and filtration capacity is modest, the effect is more concentrated and often more severe. This usually plays out in familiar ways: the system runs hotter, the response slows, pressure drifts. Valves Hydraulic power packs rely on clean fluid to perform reliably. Yet contamination - from moisture, dust, or wear particles - is the silent culprit behind most failures. H&P explores why fluid cleanliness matters, the common pitfalls in maintenance, and how simple, consistent practices can extend power pack life and reduce costly downtime. 20 HYDRAULICS & PNEUMATICS June 2025 www.hpmag.co.uk Keeping power packs running smoothly through clean fluid A technician connects a hydraulic line to a skimmer unit, highlighting the vital role of fluid cleanliness and maintenance in ensuring hydraulic power packs reliably deliver the pressure and flow needed to operate such equipment.
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HYDRAULICS R+L Hydraulics GmbH has introduced its new Spidex couplings, available in the HighTemp and UltraTemp series, specifically engineered for hightemperature applications. These elastic jaw couplings are designed to be both robust and wear-resistant, offering exceptional temperature and hydrolysis resistance. “Spidex elastic jaw couplings provide reliable performance, even under extreme conditions,” says Detlef Peick, Business Development Manager at R+L Hydraulics. “They are the result of many years of experience and continuous further development.” The UltraTemp series is particularly notable for its high temperature tolerance, capable of withstanding long-term operating temperatures of up to 180°C. “This is a unique feature within the industry,” Peick adds. The three-part couplings are axially pluggable, fail-safe, and maintenance-free, making them ideal for demanding environments such as steel mills, lime kilns, drying plants, and marine applications. A key feature of Spidex couplings is their use of high-temperature resistant elastomeric inserts, known as spiders. These components enhance durability and withstand frequent temperature fluctuations, reducing downtime and extending maintenance intervals. This, in turn, improves system availability and delivers both economic and environmental benefits. Peick explains: “The enhanced temperature resistance of our elastomer spiders allows for the reliable use of Spidex couplings in processes involving thermal processing steps. The HighTemp and UltraTemp spiders’ resistance to wear and tear in applications with frequent temperature changes contributes significantly to the durability and reliability of the system.” The UltraTemp spiders also boast superior hydrolysis resistance, allowing them to perform effectively in humid conditions, including exposure to seawater. This makes them particularly suitable for marine applications and environments with high moisture levels. Depending on size and application, Spidex couplings are capable of handling up to 11,000 Nm of nominal torque and a maximum torque of 22,000 Nm, making them well-suited for demanding tasks. Peick notes: “This superior performance combined with excellent damping properties and the ability to compensate for high radial misalignment sets new standards in the industry.” R+L Hydraulics takes pride in providing clear and transparent specifications for the operating temperature ranges of the HighTemp and UltraTemp series. “Our clients can rely on our products to deliver the promised properties,” Peick emphasises. Headquartered in Germany, R+L Hydraulics engineers and manufactures a comprehensive range of couplings and hydraulic accessories. The company is a subsidiary of US-based coupling specialist Lovejoy LLC, both of which are part of The Timken Company. For further information please visit: www.rl-hydraulics.com 22 HYDRAULICS & PNEUMATICS June 2025 www.hpmag.co.uk Elastic jaw couplings developed for high-temperature and demanding applications Elastic jaw couplings developed for hightemperature and demanding applications
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PNEUMATICS Plug-and-play pneumatic upgrade enhances safety and efficiency for kitchen manufacturer A leading kitchen manufacturer was struggling with a series of outdated pneumatic backplates which control their production lines of kitchen cupboard assemblies. Maintenance and fault-finding were challenging due to the absence of colour-coded pipework and a monitoring system. Health and safety were also a concern, as the original system had retrofitted safety components and lacked several key safety features. One of Camozzi’s premium distributors, Engineers Mate – part of the IADA group – approached Camozzi for support with the replacement of three initial backplates, one air preparation set & two valve control backplates. Representatives from Camozzi Automation, including the technical application team, along with the distributor, visited the site to meet the team, understand operational and safety issues, and discuss the customer’s requirements. The customer required three complete backplate replacements, including new valves, colour-coded pipework to support fault-finding, and as many new safety features as could be recommended. The application team at Camozzi Automation suggested the creation of a comprehensive operating circuit and full schematic drawings with clearly labelled valves to facilitate machinery maintenance. Solution The Camozzi technical application team began re-designing the backplates using the original machine manufacturer’s documentation, incorporating the new safety and performance features discussed. The team had to work within a compact space and were provided with dimensions that the backplate needed to fit, including the positions of the mounting holes to ensure ease of installation. Enhancements included: Colour-coded tubing to the customer’s specifications Dual Safemax MX monitored safety dump valves compliant with ISO 138491 (Performance Level e) to control rod lock devices on selected cylinders Camozzi also produced bespoke, dimensionally equivalent cylinders as a special order. These were manufactured in the UK specifically for the application, offering the customer a better-value alternative to the original manufacturer’s components. Once the design was approved, A kitchen manufacturer upgraded its pneumatic system with a plug-and-play solution, improving safety through monitored valves and enhancing efficiency by reducing air leaks across production lines. H&P reports. production commenced at the Camozzi Automation Centre. Result The new Camozzi backplates were successfully installed, tested, and commissioned by the customer. Following the successful implementation, discussions are now underway to replace the remaining nine backplates across other machines and production lines, as well as additional pneumatic equipment. The new panels and cylinders reduced air leaks, resulting in improved energy efficiency and associated cost savings. The system was delivered as a plugand-play solution and featured special cylinders to match the customer’s existing non-ISO models - ensuring a smooth and disruption-free upgrade. Rob Beech Director Engineers Mate commented: “The whole engineering team were very pleased with the quality of manufacture and the ease of installation. Transitioning from the old, large panels to compact, well-laid-out new ones has been a great improvement.” For further information please visit: https://www.camozzi.co.uk/ 24 HYDRAULICS & PNEUMATICS June 2025 www.hpmag.co.uk
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