www.hpmag.co.uk SEPTEMBER 2025 HYDRAULICS & PNEUMATICS VOL. 30 No. 6 SEPTEMBER 2025 p36 p30 The realities of additive manufacturing Rethinking compressed air efficiency in machinery Practical steps to ensure pneumatic systems remain reliable p26 Autonomy and the future of construction
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Tests for the Autumn Budget EDITOR’S COMMENT www.hpmag.co.uk HYDRAULICS & PNEUMATICS September 2025 3 Manufacturers are not asking for favours, but for a stable environment in which to invest and plan. ‘ ’ As we enter the last quarter of the year, the forthcoming UK budget takes on particular weight for manufacturers who are already mapping investment decisions for 2026. For firms in hydraulics and pneumatics, the fiscal framework set out this autumn will influence not only confidence but also the ability to compete with rivals in Europe, North America and Asia. The sector remains capitalintensive, energy-dependent and deeply integrated with export markets, so clarity from government is more than welcome - it is essential. Energy costs remain volatile, even as wholesale prices have eased from their peaks. Long-term support and a framework that encourages investment in lowercarbon production without layering on excessive compliance costs would be well received. Many in the industry see energy stability as the precondition for any serious decarbonisation strategy. Without it, firms are left in a cycle of hesitation, delaying upgrades and holding back on growth. Capital allowances are another priority. Frequent shifts between super-deductions, temporary reliefs and partial schemes have bred uncertainty. The hydraulics and pneumatics sector, which must continuously reinvest in high-value machinery and testing facilities, would benefit from a regime that is both generous and durable. A consistent approach would signal that the Treasury understands the pace of industrial innovation and the scale of the financial commitment it demands. Skills remain a pressing concern. Manufacturers want apprenticeships and vocational training to be more than a talking point and the subject of numerous reports and surveys. Without a steady supply of technicians, fitters and engineers, investment in plant will not translate into productivity gains. The call is for joined-up policy that treats skills as the bedrock of competitiveness rather than a secondary issue. Finally, export competitiveness cannot be ignored. Many UK-made hydraulic and pneumatic systems are destined for overseas customers, and firms want reassurance that trade barriers will not continue to add friction and cost. A budget that couples domestic investment incentives with a clearer commitment to trade support would go a long way towards restoring confidence. Manufacturers are not asking for favours, but for a stable environment in which to invest and plan. If the budget delivers on energy, capital and skills, the sector will feel it has a platform from which to compete on fairer terms. Aaron Blutstein Editor
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www.hpmag.co.uk HYDRAULICS & PNEUMATICS September 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. 26 30 6 NEWS 14 HYDRAULICS 26 PNEUMATICS Maintaining pneumatic systems is often less visible than other plant priorities. Proactive care, supported by monitoring technologies and staff training, can cut energy waste, reduce downtime and extend equipment life. Taking a structured approach helps industry unlock both financial and environmental benefits. H&P reports. 28 INTEGRATED SYSTEMS H&P examines how valve design, materials and integration are critical to delivering the safety, reliability and efficiency demanded of next-generation automotive fuel cell systems. 30 APPLICATIONS Additive manufacturing is moving from prototyping to full production in demanding sectors. H&P reports. 32 KNOWLEDGE BASE The construction industry faces labour shortages and rising demand. Autonomous and semi-autonomous machines offer a solution, transferring operator skill to technology. From enhancing safety and productivity to reducing rework, autonomy is reshaping job sites and enabling contractors to do more with fewer resources. Adam Khaw explains further. 34 BFPA Hydraulics & Pneumatics’ issue-by-issue briefing on current activities and views involving the British Fluid Power Association. 36 COMPRESSED AIR, VACUUM, AND GENERATORS 38 BCAS Our regular news and events update on the British Compressed Air Society. 40 SPECIAL REPORTS 44 NEW FACES 47 PRODUCTS & SERVICES DIRECTORY 36 Subscribe for your FREE copy now
NEWS 6 HYDRAULICS & PNEUMATICS September 2025 www.hpmag.co.uk British manufacturing companies have been lagging behind international competitors over the last two decades, with manufacturers falling dramatically down the global automation tables. Our use of robotics and AI systems is poor, with training of people in relevant digital skills to take advantage of the innovation tech, well below what is needed to catch up. A new report, Making it Smarter: Global lessons for Accelerating Automation and Digital Adoption in UK Manufacturing, launched recently by Make UK and Sage reveals that nearly half of British manufacturers identify a lack of technical skills as the biggest hurdle to improving their use of innovative advanced technologies. Those projects which do start often stall after implementation stage, because companies cannot find the help and advice they need to make the technologies work well. Countries where all SME innovation funding and advice is held under one easy-to-access ‘umbrella hub’ have dramatically higher success rates. The Government’s recent Industrial Strategy sets out how it will create a digitally literate workforce by 2035, but we simply can’t wait ten years for this to happen. Make UK is calling on Government to embed targeted funding for digital skills needed in manufacturing and engineering to accompany the existing £100m already set aside for engineering skills. For decades, South Korea has been undergoing a successful automation drive to transition from legacy production methods to advanced digitalised factories. It has stuck religiously to a single strategy, concentrating on education, infrastructure and innovation. The Government provides SMEs with bespoke incentives – offering easy to access R&D tax incentives of 30% for companies investing in semiconductor facilities, and broader tax credits guaranteed to 2029 and beyond. This certainty and confidence has led to South Korea turning into a global leader in the production of semiconductors and other advanced technologies. The South Korean Government also saw the need to make education work for industry – providing the employees to power the technologies. It committed to training 40,000 people to operate fully automated production systems and there are now no skills shortages in technical and digital innovation. The rewards are high; firms adopting smart technologies see a 25% increase in productivity and a 27% drop in defects. Singapore underwent a similar transformation, now a global leader in high-value advanced manufacturing, concentrating on the lucrative semiconductor market, precision engineering, pharmaceuticals and clean energy. Singapore’s pro-innovation environment delivers some of the most generous R&D tax incentives in the world, where companies can claim up to 400% tax deductions on local R&D or opt for a 20% cash payout. The incentives are embedded in a long-term industrial policy, giving SMEs and start-ups greater cashflow certainty and the ability to grow to their full potential. Germany has stayed top of the international performance leagues consistently over the last decade. It’s success is largely driven by embedding research institutions into local industry, with a particular focus on SMEs. Overall Germany’s successful approach blends SME-only tax relief, sector-specific research and regional accessible digital support. With a population no larger than London’s, Switzerland delivers a manufacturing output of around £150 billion — astonishingly close to the UK’s £217 billion. This remarkable productivity stems from a national strategy that prioritises advanced technologies, SME competitiveness, and long-term innovation. The Swiss Innovation Agency typically funds up to 50% of eligible project costs for SMEs, while larger firms only qualify if they partner with smaller ones. Seamus Nevin, Chief Economist Make UK commented: “Time and again, we hear from small and medium-sized manufacturers that they’re keen to adopt new technologies, but are being held back by fragmented support, complex funding systems, and a lack of accessible, appropriate digital skills training. If we want to unlock a £150 billion boost to UK GDP by 2035, we must make it easier for SMEs to adopt automation and AI. “Other countries are accelerating ahead by putting smaller firms at the heart of national strategies – with longterm support that’s simple to access, reliable, and rooted in real business needs. From South Korea to Switzerland, governments have created clear, SMEfocused strategies that simplify innovation funding, offer long-term tax incentives, and ensure every business can access practical support. “These policies work not just delivering improvements in economic growth, but also in more environmentally friendly processes with fewer defects, higher profit margins, and creating more higher skills, better paying jobs.” Sergio Braga, Product Marketing Manager, Sage added: “Sage is proud to support Make UK and the important work they do for the manufacturing sector. In today’s climate of ongoing disruption, skills shortages, and global competition, digitalisation isn’t just a growth lever — it’s a necessity. By helping SMEs embrace digital tools, we can improve productivity, build resilience into supply chains, and secure a stronger future for UK industry.” British industry is lagging behind global robotics and AI leaders
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 TESEO SOLUTIONS DELIVERED STRAIGHT TO YOU! 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
NEWS 8 HYDRAULICS & PNEUMATICS September 2025 www.hpmag.co.uk Total Pressure Solutions Ltd (TPS) has launched its operations in the UK fluid control sector. Established in 2024 and headquartered in Nuneaton, Warwickshire, the company’s stated aim is to provide advanced, precision-engineered products to support efficiency, safety, and operational accuracy across a range of industrial applications. As part of its commitment to supplying only the highestquality products, TPS also confirms that one of its flagship solutions, the Supmea Electromagnetic Flow Meter, has recently achieved UL (Underwriters Laboratories) approval. The certification, says the company, represents a milestone in product safety and compliance, giving customers confidence that the device meets globally recognised standards for performance and reliability. TPS’s core range includes pressure switches in digital, ATEX, hydraulic, and pneumatic formats. These are designed to integrate into existing systems, supporting precise control and safe operation. TPS says reliability is a defining feature of its pressure switches, which can contribute to improved energy efficiency while maintaining consistent performance. The business also supplies flowmeters, including electromagnetic, turbine, vortex, and ultrasonic models. These are intended for applications requiring accurate flow measurement with minimal maintenance. Level measurement devices form another part of the product line, with options such as radar, float, ultrasonic, and hydrostatic sensors. TPS says these are suited to environments where maintaining precise fluid levels is critical to operational success. Additional products include solenoid valves, temperature control devices, and solenoid connectors, expanding the company’s offering for industrial process applications. “We are excited to bring Total Pressure Solutions to the UK market,” says Leon Anthony, pressure, level, and flow specialist at TPS. “TPS has formed partnerships with established manufacturers to deliver tailored solutions for our customers. By working with this select group, we’re committed to providing best-in-class service and support.” TPS views its UK launch as an opportunity for industries to access fluid control and measurement products engineered for performance, durability, and operational reliability. Accordingly, the company will showcase its latest technologies at Machine Building Live 2025, a one-day exhibition taking place on Wednesday, 15 October 2025, at the National Agricultural Exhibition Centre (NAEC), Stoneleigh Park, Warwickshire. For further information please visit: https://www.totalpressuresolutions.co.uk/ Total Pressure Solutions launches in UK fluid control market SPS 2025 to focus on AI and talent development From 25–27 November 2025 the Nuremberg Exhibition Centre will host SPS - Smart Production Solutions. For more than three decades the event has been a point of reference for the automation industry, bringing together decision-makers, developers, and engineers to present advances, debate challenges, and identify emerging directions in technology. It remains one of the most established fixtures in the international industrial calendar. This year’s edition will see around 1150 companies exhibiting across 15 halls. Large international names such as Siemens, Beckhoff Automation, Phoenix Contact and Bosch Rexroth will be present, joined by a strong group of British firms including Analog Devices, Motortronics, and Mechan Controls. The range of participants reflects the breadth of the sector and the mix of longestablished players and newer businesses that continue to shape automation. Artificial intelligence will be one of the most prominent themes. AI is already being embedded into process engineering and predictive maintenance, as well as quality assurance and adaptive production control. These applications are
NEWS 10 HYDRAULICS & PNEUMATICS September 2025 www.hpmag.co.uk influencing the design of both hardware and software and raising questions about efficiency, flexibility, and resource use. “In many production environments, industrial AI is no longer a topic for the future, it is already a reality. At the SPS 2025, our exhibitors will be showing how AI is already being used in practice today and its potential for future automation applications,” said Sylke Schulz-Metzner, Vice President SPS. For visitors wanting to see how these ideas are being put into practice, SmartFactory Kaiserslautern will run guided tours twice daily. Led by specialists, they will cover companies working in both hardware and software and examine the difficulties currently encountered in implementation. “The aim of our tours is to provide targeted insights into key technologies such as artificial intelligence, digital twins, and security in system architecture. A key priority for us is facilitating the transfer of technological expertise into industrial practice,” said Dr. Ingo Herbst, press spokesperson for SmartFactory Kaiserslautern. The event is expected to draw international visitors, continuing the trend seen in previous years. In 2024, 51,291 people attended in total, 29% of them travelling from outside Germany. The UK accounted for 463 attendees, roughly 3% of all non-German guests. The appeal lies not only in the exhibition stands but also in the opportunities for exchange. Visitors can attend discussions on digital transformation, cybersecurity, Industry 4.0, and sustainable production. Speaker sessions are followed by informal conversations at neighbouring zones where questions can be pursued further. Shared booths in Hall 6 will showcase different aspects of collaboration. Automation meets IT will look at the intersection of traditional industrial systems with digitalisation and cybersecurity. The International Start-up Area will provide space for young companies from around the world to present disruptive ideas. The young INNOVATORS booth, supported by the Federal Ministry for Economic Affairs and Climate Action, will highlight the work of emerging German firms. A strong emphasis is also placed on supporting younger participants. The Makeathon, running throughout the exhibition, will invite pupils, students, apprentices, and young professionals to work in interdisciplinary teams to design prototypes in 2.5 hours, engaging directly with companies. The programme concludes with Young Talents Day, offering guided tours and one-to-one career advice for those considering a role in automation. To find out more visit: https://sps.mesago.com/nuernberg/ 7en.html Emerging technologies such as artificial intelligence (AI), machine learning (ML), and digital twins are rapidly transforming enterprise asset management (EAM), according to the latest Maintenance Trend Report from Ultimo. Yet despite this technological shift, the research underlines that effective maintenance remains fundamentally a human-led activity. The global survey of more than 200 maintenance professionals shows a sharp rise in interest in advanced technologies compared with the 2023 edition of the report. When asked which innovations would have the greatest positive impact on maintenance and business practices, 68% of respondents pointed to contextual intelligence — up from just 8% last year — followed by automation and robotics (49%) and machine learning (41%). Interest in digital twins has also more than doubled, now reaching 40%. However, alongside enthusiasm for new tools, organisations continue to face pressing workforce challenges. Nearly two-thirds (63%) of respondents cited an ageing workforce as the most significant factor shaping maintenance strategy, emphasising the need for knowledge transfer and workforce planning. Recruiting skilled staff also remains a concern, with 50% saying it had been the primary source of operational disruption in the past year. “From global instability to changing regulations, socioeconomic and political shifts are creating uncertainty across industries. In this environment, agility is critical,” said Berend Booms, Head of EAM Insights at Ultimo, an IFS company. “EAM can also serve as a catalyst for innovation. Internet of Things (IoT), AI, ML, digital twins, and predictive analytics are rapidly transforming industrial businesses. They unlock smarter decision-making, greater efficiency, and a sharper competitive edge.” The report highlights how real-time data insights from IoT devices and predictive modelling — whose perceived value has tripled since 2023 — are helping organisations unlock new opportunities in maintenance planning. Yet, almost half (49%) of respondents identified a lack of in-house expertise as a barrier to adopting these advanced tools. The findings also emphasise that while AI-enabled platforms are reshaping maintenance practices, people remain central to driving success. Modern EAM systems have evolved from static data repositories into predictive tools, helping teams shift from reactive maintenance towards proactive strategies. By combining AI with operational data, these systems can identify recurring failures, optimise workflows, and minimise downtime, effectively becoming a strategic adviser to asset managers. As the report concludes, the future of maintenance will depend on a balance of human expertise and digital intelligence. Produced in collaboration with Verdantix, TwinThread, ABS Consulting, and MaxGrip, the report is available for download at: www.ultimo.com/report Report finds emerging technologies are reshaping asset management, but people remain key
Make sure you join the celebration... In this landmark 80th Anniversary year, the AEMT Awards will once again shine a spotlight on the people, companies, and innovations driving progress in the electro-mechanical sector. The awards recognise and reward the products, 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. So whether you have submitted an entry or not, this is an industry event not to be missed. Produced by and operated by The Association of Electrical & Mechanical Trades 2025 Partners: AWARDS Book Seats at: www.aemtawards.com
NEWS 12 HYDRAULICS & PNEUMATICS September 2025 www.hpmag.co.uk Omniflex celebrates 60th anniversary Remote monitoring specialist Omniflex is celebrating its 60th anniversary, having been founded as Control Logic (Conlog for short) by John Moshal and Alan Murray in 1965 in Durban, South Africa. The duo were inspired by the potential of the newly-invented transistor. Throughout its history, the company has delivered technologically innovative solutions for key industries, including mining, nuclear, petrochemical, and oil and gas, for notable clients like Sasol, Sellafield, New South Wales Ports and Port of Melbourne. In 1965, Moshal and Murray founded Conlog leading the way in replacing bulky wiring intensive, power-hungry mechanical relays with small, elegant, electronic modules. Their secret weapon was an octal-based transistor logic module that slashed complexity and boosted maintenance performance in industrial systems. This is what caught the eye of renowned Anglo American chairman Harry Oppenheimer in the early 1970s and inspired him to provide the funding that kickstarted the company’s growth in South Africa. “Since its inception, Omniflex has been about listening, designing, tweaking and delivering exactly our customers need, even when it means pushing the boundaries of technological capabilities or going against the industry consensus,” explained David Celine, managing director of Omniflex. Flexibility and reliability became Conlog’s core principles and remain an integral part of Omniflex’s culture today. This saw the company earn the respect of engineers across key industry sectors and helped to establish the firm as the leading experts for complex, high-stakes industrial automation. The company is sharing its highlights from each decade of its history in a series of blogs on its LinkedIn account. Engineering and technology courses have seen the largest increase in placed applicants in this year’s university admissions, according to new data released on A Level and T Level results day in August. The figures also show that, for the second year in a row, STEM subjects have grown in popularity, with mathematics remaining the most popular A Level subject. While demand for engineering at university and college is rising, research from Universities UK has highlighted a reduction in funding allocation for so-called “high-cost” courses such as engineering. This trend is seen as a concern, given that the Government’s Industrial Strategy identifies engineering skills as “at the heart” of several priority growth sectors. The Institution of Mechanical Engineers is continuing to urge the government to support the university sector in addressing the gap between demand and funding for high-cost courses. This year also marks the second cohort of students completing the Engineering and Manufacturing T Level. Sector bodies say they are closely monitoring the destinations of these learners. Alongside T Levels, BTEC and other vocational qualifications remain important routes into engineering careers, providing pathways to apprenticeships and technical roles. Employers and sector organisations, including members of Skills England, have committed to working together to ensure regional opportunities are available for young people entering the engineering workforce. Surge in demand for engineering courses
HYDRAULICS Micron Eagle Hydraulics real-time monitoring system is designed to transform how industries manage critical fluids, cutting downtime, costs and waste. For decades, fluid analysis in hydraulics and other industrial applications has relied on manual sampling and lab testing - a slow, snapshot-based process prone to contamination and error. Micron Eagle Hydraulics’ technology aims to change that. The company’s Fluid-fitness Remote Online Guardian (FROG) continuously monitors hydraulic fluids, lubricants and fuels, offering predictive intelligence and live alerts. Part of Micron Eagle’s Fluid Fitness Technology (FFT)programme, it gives maintenance teams immediate insights into contamination, temperature, humidity and pressure via a cloud-based dashboard accessible onshore and offshore. “FROG is a genuine industry game-changer and has already been adopted by a major operator that immediately realised its benefits,” said Mark Burnett, Business Development Director at Micron Eagle Hydraulics. “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.” By moving beyond traditional lab-based testing, FROG delivers continuous, live data that empowers proactive maintenance. Trends can be identified early, anomalies flagged instantly, and costly downtime avoided. With the ability to reduce unnecessary fluid disposal, the system also supports sustainability goals by minimising waste and hazardous handling. FROG’s sensors track multiple parameters and allow users to set thresholds for custom alerts. The platform integrates advanced analytics to reveal subtle patterns, enabling smarter decision-making and asset optimisation. Combined with a fluid conditioning unit, the solution is already under contract in the UK, Middle East and Africa. The development of FROG was led by director Henry Nagel in Blackburn, Aberdeenshire. FROG’s potential spans several heavy-use industries: Oil & Gas – ensuring reliability of critical offshore equipment in harsh environments. Manufacturing – extending the life of hydraulic presses and production machinery. Transportation – helping operators reduce costs while meeting sustainability targets. Power Generation – protecting turbine and generator fluids to prevent outages. Poor monitoring can mean high costs, from component failures and downtime to fluid replacement and disposal. FROG addresses these risks directly, providing what Micron Eagle calls a “vital live overview” of industrial assets. Mark Burnett added: “With FROG, we are entering a new era of fluid information management. It’s more than a product; it’s an ally in achieving industrial excellence. It is the vital fluid monitoring system for your assets - one that is live, that communicates and can be accessed remotely. The market has already responded extremely positively to this innovation due to its capability to support decision-making when it comes to operational efficiency, reducing costs and supporting sustainable practices.” For more information visit: https://www.microneagle.com/fluid-fitness-technology/ https://www.microneagle.com/frog/ 14 HYDRAULICS & PNEUMATICS September 2025 www.hpmag.co.uk Real-time fluid condition monitoring enhances maintenance and reliability
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HYDRAULICS 16 HYDRAULICS & PNEUMATICS September 2025 www.hpmag.co.uk Should you opt for custom or off-the-shelf bearings? For engineers working under tight deadlines or within budget constraints, off-the-shelf bearings often provide the most practical solution. These bearings are mass-produced, ensuring consistent availability and significantly reducing lead times compared to custom alternatives. Their large-scale manufacturing also benefits from economies of scale, lowering costs without compromising quality. What’s more, off-the-shelf bearings undergo rigorous standardisation and testing to meet industry standards, like ISO 281, bearing life calculation and ISO 492, tolerance classes for rolling bearings. Compliance with these standards ensures predictable performance and reliability across a wide range of applications, from industrial machinery to aerospace systems. Another key advantage of off-the-shelf bearings is their versatility. With a broad range of options designed to accommodate different loads, speeds and environmental conditions, they are widely used across industries, including automotive, medical and manufacturing sectors. When custom bearings are necessary While off-the-shelf bearings are suitable for many applications, some scenarios require a more tailored approach. Custom bearings are specifically designed to meet unique specifications such as nonstandard sizes, extreme operating conditions or specialised load capacities. The aerospace industry is increasingly using custom parts and components to enable more diverse and specialised aircraft designs. For instance, industries like aerospace and medical devices often require bearings with high precision — meaning tight dimensional tolerances, low friction and consistent rotational accuracy. These bearings must also be resistant to harsh environments and capable of functioning under high speed or heavy load conditions. Custom bearings allow engineers to address these challenges, ensuring optimal performance and durability. However, custom solutions come with trade-offs. The design and manufacturing process often require significant time and investment, resulting in higher costs and longer lead times. Engineers must carefully evaluate whether the added benefits of custom bearings justify these challenges. Custom or off-the-shelf — how do you decide? When making the choice between custom and off-the-shelf bearings, it is crucial to assess several key factors to ensure the most suitable choice for your application. First, consider the specific requirements of your application. Are there unique operating conditions - such as high temperatures, unusual loads or non-standard dimensions — that off-theshelf bearings may not be able to address? If the answer is yes, then custom bearings may be the better option. Next, evaluate the project’s budget. Custom bearings often involve higher manufacturing and design costs, so it’s important to determine whether the additional expense aligns with any financial constraints. Alongside costs, lead time is another consideration. Deloitte reported in its 2025 Manufacturing Industry Outlook that despite lead times have shown improvement since pre-pandemic levels, global supply chain disruptions persist. It predicts that companies are expected to face continued supply chain risk in 2025, due to factors like geopolitical tensions, labour shortages and rising input costs. Custom bearings typically require longer production timelines, which could impact your overall schedule. If a faster turnaround is essential, off-theshelf bearings might be more practical. Finally, think about the performance trade-offs. In some cases, off-the-shelf bearings can be adapted to meet specific requirements through modifications, such as relubrication or material coatings. For example, thin dense chromed (TCD) plating can be applied to improve wear resistance, reduce friction and improve corrosion resistance — ideal for harsh environment like food processing or marine. This approach can achieve the desired performance improvements in a costeffective manner, bridging the gap between standard and custom solutions. In cases where off-the-shelf bearings almost meet the requirements, additional customisation — like applying specialised lubricants — can improve performance without the need for fully-customised designs. For example, perfluoropolyether (PFPE) lubricants are commonly used in aerospace and vacuum applications because of its excellent thermal stability and resistance to extreme temperatures. Polyurea-based greases offer excellent oxidation stability and are ideal for highspeed electric motor bearings, while food grade lubricants ensure compliance with safety regulations in food and pharmaceutical processing. This approach offers a middle ground, balancing cost efficiency with tailored performance. By thoroughly evaluating these factors, engineers can make informed decisions that balance functionality, cost and efficiency. The decision between custom and offthe-shelf bearings ultimately comes down to striking the right balance between functionality, cost and efficiency - three factors that directly influence overall machinery performance, durability and long-term value. By understanding the demands of the application and exploring ways to enhance standard bearings through relubrication or coatings, engineers can often achieve high-performance outcomes without the cost and lead time of a fully custom solution. *Chris Johnson is managing director of bearing specialist SMB Bearings For further information please visit: http://www.smbbearings.com/ Bearings are essential for reducing friction, supporting loads and ensuring smooth operation in machinery, including hydraulic equipment. The decision between custom designs and readily available standard parts is not just about cost - it can also affect lubrication needs, reliability and long-term performance. Chris Johnson* weighs up the advantages and disadvantages.
www.hpmag.co.uk HYDRAULICS & PNEUMATICS September 2025 17 Next Level Corrosion Protection VOSS coat Zinc + passiva琀on + sealer Comparison of the salt spray chamber test a昀er 720 hours VOSS zinc-nickel www.tom-parker.co.uk sales@tom-parker.co.uk 01772 255109 Unrivalled Strength. Unmatched Durability. When performance and reliability are non-nego琀able, choose VOSS, the world’s trusted name in 昀uid-system connec琀on technology. Engineered in Germany, their premium hydraulic compression 昀 ngs are designed to excel in the toughest environments, delivering unparalleled durability and corrosion protec琀on. Why Choose VOSS? • Superior Corrosion Resistance: Proven to withstand over 1,000 hours of harsh condi琀ons with their unique, patented advanced VOSS coat technology • German Engineering: Precision-engineered for high-performance, safety-cri琀cal applica琀ons • Ready When You Are: In stock at Tom Parker Ltd, your authorised UK distributor, with same-day despatch for fast delivery Trust VOSS for 昀 ngs that outlast and outperform. Contact Tom Parker Ltd today to enhance your hydraulic systems with VOSS quality! Eaton’s Filtration Division has expanded its product line with three new filter series - the DUA, LWF, and DNR - designed to provide reliable performance across a range of industrial applications, including power generation, manufacturing, and marine systems. “As pressures mount to safeguard critical processes and minimise downtime, having a dependable filtration solution that can operate uninterrupted is essential,” said Simone Ortner, Hydraulic Filtration Engineering and Product Manager at Eaton’s Filtration Division. “Our new filters are tailored to meet the practical needs of industries facing challenging conditions and tight operational schedules.” The DUA series extends Eaton’s existing DU filter line with a duplex design that meets ASME, PED, and EN 13445 requirements. The design allows operators to divert filtration flow from one side to the other, helping to maintain continuous operation. A clogging indicator can be attached directly to the switch gear housing without additional piping. The DUA filters operate at pressures up to 320 psi (22 bar) with flow rates of 1,056 gpm (4,000 l/min) and are available in sizes 2005, 3005, and 4005. Typical applications include power plants, manufacturing facilities, and marine systems. The new LWF series is designed for flexibility, with installation possible on suction, pressure, or return lines. It uses the pleated 01.E1501 filter element, which increases dirt-holding capacity, and supports various filter media types and grades of filter finesse. The series handles operating pressures up to 232 psi (16 bar) and flow rates between 396 gpm (1,500 l/min) and 1,585 gpm (6,000 l/min). Options include stainless steel (ELWF) and ASME design (LWFA, ELWFA) versions. Eaton’s DNR duplex filters are intended for systems requiring uninterrupted operation, such as turbine and gearbox lubrication. A three-way changeover valve allows for filter element replacement without shutting down filtration. The carbon steel housing accommodates Eaton’s 01.NR630 and 01.NR1000 elements, offering adaptability for different setups. The series is rated for pressures up to 232 psi (16 bar), now available in sizes 5265 and 7265, and also offered in stainless steel (EDNR) and ASME designs (DNRA, EDNRA). “By combining advanced design with different housing material options, these filters address the increasingly complex challenges of modern hydraulic and lubrication oil systems, ensuring optimal performance and peace of mind for their operators,” adds Ortner. For further information please vist: https://www.eaton.com/gb/engb/products/filtration-solutions.html Expanded filtration solutions ASME-certified, DUA duplex pressure filters ASME-certified, DUA duplex pressure filters DNR duplex pressure filter series
HYDRAULICS From farms and factories to complex industrial plants, hydraulic systems are the quiet workhorses of the UK economy. They keep production lines moving, power essential machinery, and underpin countless critical operations. But as the sector evolves, businesses are recognising the need for greater consistency in quality, testing, and training to keep pace with rising demands on performance and safety. Too often, hoses and fittings are mismatched. Too often, parts are bought on price alone, with little attention paid to certification. And too often, the people assembling and maintaining these systems have learned through trial and error, without formal guidance. It is a combination that can work, until it doesn’t. Failures bring downtime, costly repairs, and in the worst cases, life-changing injuries. That is the backdrop against which Evofluid Hydraulics UK and Oleodinamica & Pneumatica (O&P) have launched a partnership aimed not just at supplying products, but at helping the industry rethink its approach to safety, efficiency, and competence. “It’s about more than supplying parts or machines,” says Stefan Gunter, Business Development Manager at Evofluid Hydraulics UK. “Our industry needs to think in terms of systems, where every component is matched, tested, and supported, and where the people using those systems have the knowledge to do their jobs safely and effectively.” Catastrophic consequences The case for change is stark. Stefan describes a past visit where the fittings being used “looked fine on the bench” but had no testing records, no certification, and no way to prove compatibility. “I’ve seen situations where an operator asks their supplier for documentation and gets nothing,” he says. “That lack of traceability is a real risk. You don’t know what you’re fitting, or what it’s been tested for.” The consequences of that uncertainty are all too real. “If you’ve ever stood next to a hose when it fails under pressure, you’ll know how serious it can be,” says Stefan. “A few years ago, I witnessed the aftermath of a case where the wrong pressure rated adaptor had been used to test a hose. When it failed under full pressure, the bang shook the building - it was like an explosion. The Perspex on the test rig shattered, with shards narrowly missing the operator. “The operator was frozen in shock. He was barely able to speak with the shock for a day or two afterwards. Thankfully, nobody was hurt, but many people haven’t been so lucky. There have been countless serious injuries and even fatalities in the industry from hydraulic failures. “And it’s not just the immediate danger. Think about the indirect consequences. If a hose fails in a lift, on agricultural machinery, or even on a plane, the risk to people and equipment multiplies. It’s simply not worth cutting corners when the stakes are that high.” A system, not a shopping list The partnership between Evofluid and O&P is designed to tackle those issues head-on. Evofluid serves as the UK commercial branch of Hydro Holdings S.p.A., a European manufacturer of carbon steel and stainless-steel hydraulic components. This strategic position gives Evofluid the ability to maintain strict quality control and deliver quickly from extensive UK-based stock. By combining that local manufacturing strength with O&P’s 44 years of expertise in hose and tube processing equipment, the two companies offer something many operators say they need but rarely find: a complete, end-to-end system. O&P’s machines - crimpers, cutters, skivers, flushing rigs, and test rigs - are engineered for reliability and ease of use. The greasefree crimping heads and fixed six o’clock die positions make operations faster and more consistent, while Siemens touchscreens, fully supported in the UK, allow quick backups and cost-effective repairs, reducing downtime. “It’s about giving customers confidence,” Stefan explains. “Confidence that the components they’re using are certified, that the assemblies are matched and tested, and that the equipment they’re working with is dependable and supported locally.” Training as a foundation, not an add-on Evofluid and O&P see training not as an optional extra but as the foundation for safer, more efficient operations. They have committed to a programme to offer subsidised, BFPA-accredited courses designed to embed knowledge and best practice across the sector. Flexibility is key: courses can be delivered onsite, online, or at a training centre, making them accessible whether you are a oneperson workshop or a major industrial operator. The training courses includes: Hose assembly skills – Core techniques for building safe, consistent assemblies. Hose integrity, inspection, and asset management – Identifying wear, preventing failures, and extending service life. Hydrostatic proof pressure testing – Proper testing procedures for certification and quality assurance. Level 2 hydraulics and Level 1 pneumatics – Building deeper technical understanding for technicians and engineers. 18 HYDRAULICS & PNEUMATICS September 2025 www.hpmag.co.uk Putting training and quality at the heart of hydraulics H&P’s Aaron Blutstein speaks to Stefan Gunter, Business Development Manager at Evofluid Hydraulics UK, and Alberto Gogazzi, Area Sales Manager at Oleodinamica & Pneumatica (O&P), about their new partnership. They discuss how the collaboration aims to tackle long-standing challenges in the hydraulics sector, from mismatched assemblies, re-ending, and inconsistent training to the need for locally supported, high-quality solutions that improve safety, reliability, and efficiency across the industry.
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20 HYDRAULICS & PNEUMATICS September 2025 www.hpmag.co.uk HYDRAULICS Hydraulic Hose Crimpers in Stafford We are the largest UK stockist for Hydraulic Hose Crimpers, Cutters, and Accessories in the UK New Machines 137 Ton up to 350 Ton c/w dies, quick change and benches Mobile Van units. 12 Volt for 1.1/4 and 2 inch Multi We have a range of used Machines, 240 V / 3 phz and 12v DC, Neotech, Techmaflex, Hydralok, Uniflex, Finn power and Banner We are the Main UK stockist For B Fluid. All in stock, Hose racks, coilers, Skivers, Measure devices, Hand Crimpers The full range of cutters, floor mount and Bench, Pushers, tube flare Machines and Hydraulic Benders We now kit out Mobile hose vans, with or without your own Equipment, Mobile service engineer covering all of the UK Call any time on 07484 760684 kevin@hydraulichosecrimpers.co.uk Hydraulic Hose Crimpers, Unit 3, Billington Farm Industrial Park, Billington, Stafford, Staffordshire. ST18 9DQ Please visit our website: www.hydraulichosecrimpers.co.uk Leadership and management academy – Equipping supervisors to drive a culture of quality and safety in their teams. “Training isn’t optional,” Stefan says. “When a technician understands not just what to do but why it matters, you get better assemblies, fewer failures, and safer workplaces. That knowledge pays for itself many times over.” Beyond the classroom Structured courses are only part of the offer. Evofluid and O&P are building what Stefan calls “continuous support”, with tools and services that help businesses maintain high standards long after the training day ends. This includes: Hose health checks to identify risks early. Cost-effective machine calibrations in line with BFPA recommendations. Technical guidance for hose production and asset management. Safety literature, including standards cards, quick-reference posters, and fluid injection guidance. Support for hose restraint systems such as Stopflex+. “Training has to be ongoing,” Stefan explains. “You don’t create a safety culture with a single session; you do it by making learning part of the job, by keeping people informed and confident every day.” Alberto Gogazzi, Area Sales Manager at O&P Srl, agrees: “Selling quality products is important,” he says, “but supporting customers with knowledge is what builds trust. That’s what drives long-term change.” The partnership also tackles a technical problem that has plagued the industry for years: mismatched assemblies. By integrating Evofluid’s certified fittings, including the OneGC stainless-steel ferrule, compatible with up to ten different hose types, with O&P’s precision machinery, operators can build assemblies that are consistent, compliant, and easier to maintain. Lean production and efficiency Safety is only part of the story. The partnership is also about efficiency. Evofluid’s Lean Production Guarantee, which focuses on eliminating waste, improving processes, and maintaining quality, has helped customers cut downtime and reduce errors, with some seeing cost savings of up to 30%. Inventory simplification is a key part of this. “When you can reduce the number of SKUs without compromising compatibility, you make the process leaner and less prone to mistakes,” Stefan explains. O&P’s machines play their part too. Grease-free crimping heads and fixed six o’clock die positions make operations faster and more consistent, while Siemens touchscreens, fully supported in the UK, mean data can be backed up quickly and parts replaced without the delays that often come with overseas support. Local support, faster response For many UK operators, the weakest link has been service and support. When machines fail, waiting weeks for overseas parts or technicians can turn a minor fault into a major disruption. Evofluid has invested in UK-based stock and trained service technicians to close that gap. “When a machine goes down, you can’t afford to wait weeks for help,” Stefan says. “By having parts and expertise here in the UK, we can get customers back up and running quickly and costeffectively.” For both Evofluid and O&P, this partnership is about more than commercial growth. It is about raising standards across the industry. “This isn’t just about our customers,” Alberto says. “If we can help raise standards for everyone, operators, suppliers, and endusers, that benefits the entire sector. Quality, compatibility, and training shouldn’t be optional. They should be the baseline.” Stefan agrees: “This is about investing in the future. Safer systems, leaner processes, and better-trained teams don’t just make sense for today, they build resilience for tomorrow.” Investing in a safer, smarter future In an industry where cost pressures are ever-present, the temptation to cut corners is ever-present unfortunately. But as Stefan points out, the long-term risks far outweigh the short-term savings. A mismatched fitting or an untested assembly doesn’t just threaten equipment, it puts people, productivity, and reputations on the line. By embedding training and continuous support alongside matched systems and locally backed equipment, Evofluid and O&P are reframing what good practice looks like. They are making quality and safety accessible, scalable, and sustainable for businesses of every size, from independent workshops to major industrial operators. Stefan puts it simply: “Training isn’t about selling. It’s about building trust and giving people the tools to do their jobs safely and effectively. If we can help raise standards, not just for our customers but across the industry, that’s a win for everyone.” For operators, the message is clear: investing in quality, compatibility, and competence isn’t a luxury. It is the foundation of safer, leaner, and more resilient operations. And for an industry where failure can carry such high costs, that investment has never mattered more. For further information please visit: www.evofluid-hydraulics.com or www.op-srl.it
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