www.hpmag.co.uk OCTOBER 2025 HYDRAULICS & PNEUMATICS VOL. 30 No. 7 OCTOBER 2025 p38 p26 The evolving role of hydraulics in automation LAMMA Preview When pressure tests the limits of a seal p14 Keeping the blades turning
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Budget choices will shape fluid power EDITOR’S COMMENT www.hpmag.co.uk HYDRAULICS & PNEUMATICS October 2025 3 The Budget needs to recognise the strategic role fluid power plays in UK industry. ‘ ’ Artificial intelligence is now a routine part of operations in many plants and facilities across the UK. Predictive maintenance, data analytics, and machine learning are improving asset reliability and cutting downtime. But in hydraulics and pneumatics sectors that underpin manufacturing, energy, and infrastructure progress depends on whether the November 2025 Budget delivers the right mix of incentives and investment. Without targeted policy support, many firms risk being left behind in the shift towards digitalised, low-carbon production. The Budget needs to recognise the strategic role fluid power plays in UK industry. Hydraulics and pneumatics are vital to automation, materials handling, and transport systems, yet much of the equipment in use is ageing and energy intensive. Tax relief for upgrading to digitally connected, energy-efficient systems would help companies cut costs and emissions. Extending full expensing or introducing enhanced capital allowances for automation, sensors, and condition-monitoring equipment would make a tangible difference, particularly for small and medium-sized suppliers. Investment in digital infrastructure should also be a priority. AI-enabled maintenance and digital twins rely on high-quality data and reliable connectivity. Many smaller plants still lack the networks needed to capture and process operational data effectively. A dedicated industrial digitalisation fund, supporting cloud integration, data standards, and cybersecurity in manufacturing, would allow the hydraulics and pneumatics sectors to deploy predictive technologies at scale rather than in isolated trials. The Budget must also address the skills gap. Fluid power engineering is traditionally strong in mechanical expertise, but the workforce now needs digital literacy data interpretation, control integration, and software maintenance. Funding for apprenticeships and midcareer retraining in mechatronics and industrial data science would help ensure that AI and automation complement, rather than outpace, the existing skills base. The creation of regional training hubs, jointly supported by industry and government, would allow smaller firms to access this capability without prohibitive cost. The sector would also benefit from a dedicated innovation challenge - similar to those run through Innovate UK - focused on energy-efficient hydraulic systems, electrified actuation, and smart control architectures. Providing matched funding for R&D projects that apply AI and digital twins to fluid power would accelerate development and encourage collaboration between manufacturers, suppliers, and universities. Long-term industrial competitiveness depends on stable policy frameworks that give firms the confidence to invest. Committing to multi-year funding for manufacturing innovation, and ensuring that decarbonisation policy recognises the role of efficient hydraulic and pneumatic systems, would provide that certainty. Digitalisation is already reshaping maintenance and manufacturing, but for hydraulics and pneumatics, the coming Budget will determine whether this transformation spreads across the whole supply chain or remains concentrated among a few large players. With the right fiscal measures, investment incentives, digital infrastructure, targeted skills funding, and stable policy, the UK can secure a stronger, more efficient, and more resilient fluid power industry for the decade ahead. Aaron Blutstein Editor
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www.hpmag.co.uk HYDRAULICS & PNEUMATICS October 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 H&P is a controlled circulation magazine, published 8 times a year. Please contact DFA Media with any subscription enquiries. Paid subscriptions are also available on an annual basis at £110.00 (UK), £145.00 (Europe) or £180.00 (Rest of the World) P+P included. The content of this magazine, website and newsletters do not necessarily express the views of the Editor or publishers. The publishers accept no legal responsibility for loss arising from information in this publication. All rights reserved. No part of this publication may be produced or stored in a retrieval system without the written consent of the publishers. 28 30 6 NEWS 14 HYDRAULICS Even the best seal is only as strong as the pressure it’s designed to contain. Understanding how pressure and load interact helps prevent wear, leaks, and costly downtime. 28 APPLICATIONS As hydraulics and pneumatics systems become increasingly digital and connected, a shortage of skilled engineers is threatening uptime and efficiency across UK manufacturing. To close the gap, more businesses are partnering with external service specialists who bring advanced expertise, predictive maintenance know-how, and in-house training support - helping the sector build resilience and develop the next generation of fluid power talent. H&P reports. 24 PNEUMATICS 26 INTEGRATED SYSTEMS 30 KNOWLEDGE BASE 32 BFPA Hydraulics & Pneumatics’ issue-by-issue briefing on current activities and views involving the British Fluid Power Association. 34 COMPRESSED AIR As manufacturers face rising energy costs and tighter sustainability targets, attention is turning to industrial gas supply. In laser cutting, on-site nitrogen generation is helping firms cut emissions, improve reliability, and gain control over costs while supporting cleaner, faster production and more flexible, scalable manufacturing operations. H&P spoke to Andrew Butler, Business Development Manager for Industrial Gases at Atlas Copco. 36 BCAS Our regular news and events update on the British Compressed Air Society. 38 SPECIAL FOCUS In January 2026, the NEC in Birmingham will once again host the LAMMA Show, the UK’s largest exhibition dedicated to agricultural machinery, technology and services. H&P reports. 45 NEW FACES 46 PRODUCTS & SERVICES DIRECTORY 38 Subscribe for your FREE copy now Printer: Warners, UK © Copyright 2025, DFA Manufacturing Media Ltd ISSN 1366-1981 Audit Bureau of Circulation – Average net circulation 10,015 January 2024 to December 2024
NEWS 6 HYDRAULICS & PNEUMATICS October 2025 www.hpmag.co.uk UK manufacturing climbs one place to 11th in global rankings The UK’s manufacturing sector has improved one place to 11th in the latest world rankings according to the latest official figures available published by Make UK. This comes after the sector dropped out of the top ten for the first time in the previous data. The figures are contained in the latest annual ‘Manufacturing – The Facts’ which contains a wide variety of data about the vital contribution of manufacturing to the UK economy including exports, sectoral breakdown, how UK industry compares to other nations, jobs and salary levels. The data shows that in 2023 (the latest year for which global comparisons are available) UK manufacturing output was worth a revised $279bn. This is one place behind Brazil ($290bn) which has moved back into the top ten for the first time since 2012. China is by far the largest manufacturing nation with output worth $4.8trn, followed by the United States $2.8trn and Japan $840bn. Germany remains the biggest manufacturing nation in Europe by some distance ($838bn) and retains its position as the world’s fourth largest manufacturing nation. It is followed by South Korea and India who have swapped places in fifth and sixth respectively, and Mexico. Italy and France are respectively the second and third largest manufacturing nations in Europe at 8th ($353bn) and 9th globally ($296bn). Dr Seamus Nevin, Chief Economist at Make UK, said: “These figures reflect not just the importance of manufacturing to the economy but factors and trends which are redrawing the contours of the global economy at an accelerating rate. These trends reinforce why it was vital to introduce a long-term industrial strategy to take competitive advantage of our undoubted strengths. This will ensure the UK retains its place at the top table of advanced manufacturing nations where it has many world class sectors.” The importance of manufacturing to the UK economy overall is reinforced by latest data showing it accounts for more than four tenths of exports (42%), almost half of business R&D (48%) and almost a fifth of business investment (17%). Furthermore, analysis continues to dispel the myth that manufacturing jobs are badly paid when, in contrast, the average manufacturing salary at £41,220 is significantly higher than the average of the economy overall at £38,224 and services £37,559. In terms of exports, the United States remains the single largest market for UK goods worth £59.3bn in 2024. Germany is the second highest destination (£32.1.bn) while The Netherlands is third (£27.9bn). However, Make UK cautioned that trade with The Netherlands could be inflated artificially by goods being routed through Rotterdam for onward travel to other destinations. Ireland is the fourth largest export market (£23.9bn) Seven of the top ten export markets are now in the EU, worth approximately £143bn. This is more than twice the level of exports to the US and around nine times the amount to China (£16.7bn). According to Make UK, this highlights the continued importance of the EU for UK goods and the need for the Government to continue to smooth out trade barriers with what remains overwhelmingly the UK’s dominant global export market. By sector, food and drink is the biggest individual contributor to manufacturing Gross Value Added (18%), followed by the Transport sector (largely aerospace and automotive) at 17% and Chemicals and Pharmaceuticals (13%). The importance of the Transport, Chemicals and Pharmaceuticals sectors is also illustrated by the fact they account collectively for 70% of manufacturing R&D. The North West remains the biggest manufacturing area of the UK, worth £29.5bn in output and employing 335,000 people. The sector accounts for almost 15% of the North West economic output overall and almost 10% of regional employment. Wales has the highest share of manufacturing of any area of the UK, accounting for almost 16% (15.6%) of the Welsh economy. This compares to just under 10% national average.
NEWS 8 HYDRAULICS & PNEUMATICS October 2025 www.hpmag.co.uk The ERA Foundation has marked its 25th anniversary by celebrating more than two decades of investment in engineering and manufacturing engagement, including the funding of hundreds of projects worth over £20 million, and by awarding the 2025 Clark Prize to four teachers across the UK. At a special event at the Royal Society in London, Sir John Lazar CBE FREng, President of the Royal Academy of Engineering, gave a keynote speech on the Academy’s strategy and focus on skills for engineering. He was joined by ERA President Sir Alan Rudge CBE FREng, Chair Andrew Churchill OBE FREng, and 130 guests to toast the support of a long list of pro-engineering activities, from value-creating enterprise hubs to engineering fellowships and teachers whose work has showcased engineering to school children across the UK. Sir John emphasised the importance of inclusive skills development: “Equity, diversity and inclusion is a vital thread through all three goals [of the Academy’s strategy] because we can’t talk about delivering positive outcomes for people without talking about how engineering designs for all of society, and how engineers therefore need to reflect all of society.” The Foundation has played a central role in shaping engineering opportunities, from funding 55 industrial fellowships and over 100 Arkwright Engineering Scholars, to helping establish the Royal Academy of Engineering Enterprise Hub. Ranked among the top three enterprise hubs in the UK and 14th in Europe by the Financial Times and Statista, the Hub has supported over 600 researchers and entrepreneurs and contributed to nearly 6,000 jobs. Highlighting the Foundation’s reach into schools, the annual Clark Prize - named after former ERA Executive Secretary Dr David Clark - recognised four inspirational teachers for their commitment to bringing engineering into the classroom. Lucy Hart of Caroline Haslett Primary School in Milton Keynes and Tracey Ellicott of East Wemyss Primary School in Fife won the primary category, while Clare Doherty of St Mary’s College, Derry, and Dewi Thomas of YGG Bro Edern in Cardiff won at secondary level. Each school receives £12,000 over three years to support their STEM engagement projects, with the teachers also receiving individual awards. This is the first year that the prize has been awarded to two teachers per category, and the first time that schools from all four nations of the UK are represented. “The winning teachers of this year’s Clark Prize are outstanding; it is quite overwhelming to see the amount of work they devote to connecting engineering and manufacturing with school pupils,” said Andrew Everett, executive secretary of the ERA Foundation. “Their biographies speak for themselves. The Clark Prize will continue to identify and reward hard-working STEM teachers and schools, and we know there are many more out there.” Churchill added: “It is very exciting to celebrate the commencement of our 25th year of the ERA Foundation. We are very privileged to be custodians of a foundation that has the means to support such an array of brilliant projects right across the spectrum, from big investments like the Royal Academy of Engineering’s ‘Enterprise Hub’, which has funded over 600 entrepreneurs, to the primary schools of teachers such as Lucy Hart and Tracey Ellicott, who infectiously share the excitement of engineering with school children from a young age.” Dr Hayaatun Sillem CBE, CEO of the Royal Academy of Engineering, said: “We congratulate the ERA Foundation on its inspiring work to promote and enable future engineering innovation and skills over the last quarter of a century. I am delighted to be able to work with this farsighted organisation, which has played such an active role in supporting the work of our Academy and particularly our successful and growing Enterprise Hub.” Since its founding, the ERA Foundation has collaborated with a wide range of partners, from STEM Learning and EngineeringUK to the Smallpeice Trust, while also embracing digital platforms such as Born to Engineer to connect new generations with careers in engineering. With its influence now stretching across research, enterprise, schools and social media, the Foundation remains a quiet but powerful force in advancing UK engineering. ERA Foundation marks 25 years with celebration of engineering and Clark Prize for teachers
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NEWS 10 HYDRAULICS & PNEUMATICS October 2025 www.hpmag.co.uk Over 1000 students from across the country showcased innovative solutions at London’s Barbican Centre this month for the grand finals of The National Careers Challenge, where students pitched their ideas to panels of industry judges. The event saw the youngest cohort, Year 7 students, aged 11-12, tackle a clean energy challenge set sponsored by Air Products, a world-leading industrial gases company. Air Products’ brief for the Year 7 pupils was focused on how gases can be used to reduce carbon emissions in towns and enable sustainable living. It also highlighted that achieving net zero affects every part of daily life – from the infrastructure we rely on, to the products we use, our homes, heating, and travel. The challenge aimed to provide the students with a valuable opportunity to apply science, technology, engineering, and mathematics (STEM) skills to practical, real-world scenarios focused on achieving positive sustainability outcomes. The team from Mossbourne Community Academy took home the winning trophy on the strength of their project Loch Haven. Kay Benjamin Richardson, the student captain of the Mossbourne Community Academy team said, “The experience was new, challenging and of course it was fun, being different to our routine lessons. It took some trial and error and debate to work out how best to design our town and make sure our ideas were logical – it was good to be able to use our Science and Geography knowledge to solve realworld problems. All the other teams did very well too, but my team and I were thrilled to represent Mossbourne at the finals – and win!” Abbie Crunkhorn, higher education and careers manager at Mossbourne added, “It is always incredible to see the creativity and problem-solving skills of the students kick in when presented with a challenge. But more than that, they are also able to develop soft skills that they will need in the workplace such as listening, speaking, leadership and teamwork. Such challenges go to show that businesses can absolutely get involved at this level to help students understand what working with STEM projects looks like.” The annual challenge underpins one of the most important needs to support the UK’s growth and energy transition – building the skills pipeline for the future. Community and STEM Ambassador at Air Products, Lynn Willacy said, “The recently launched Industrial Strategy marks skills development as crucial to driving the UK’s economic growth. At Air Products, we firmly believe in the benefits of early engagement, enabling young students to discover the huge potential of STEM subjects. Industrial gases have a huge range of applications – whether it’s hydrogen to lower carbon dioxide (CO2) emissions in transport, or oxygen to lower the amount of energy needed to heat furnaces.” The National Careers Challenge was established in 2013 by the Inspirational Learning Group to connect classrooms with workplaces and businesses. This year’s edition saw record participation with students developing practical skills while exploring diverse career paths for the future. National Challenge inspires students to pursue a future in STEM Public perception lags behind industry on sustainability On July 24 this year, the world reached the earliest ever Earth Overshoot Day – the day on which the global demand of ecological resources exceeds what the planet will generate per annum. The UK reached it much earlier on May 20th but has pushed that day back by 40 days since the first Earth Overshoot Day in 2006, when the country’s overshoot day fell on April 10. These dates highlight the extent to which our consumption overshoots sustainable limits – and how efforts by UK industry are already making a difference. The latest Attitudes to UK Industry (ATUKI) survey, launched to the technical press at a First Friday Club Editors’ Briefing on September 5, reveals that UK consumers are largely unaware of the scale and impact of the significant strides that industry is making in sustainability practices – which will contribute greatly to pushing the date back. In 2025 the UK exhausted its annual share of global resources on 20 May, pushing its country overshoot day back by 40 days from 10 April in 2006, when the calculations first began. The Department for Energy Security & Net Zero reported in February 2024 that UK has cut emissions by 50% between 1990 and 2022, largely due to cutting emissions from energy generation, because of a shift away from using coal to using renewables. In 2012, coal provided almost 40% of UK electricity, now it’s use is approaching zero – a huge step toward Net Zero targets. However, the ATUKI report shows that the UK public understanding of what Net Zero means in practice remains limited. The ATUKI report demonstrates the need for better alignment between industrial sustainability action and public perception. Executive Summary, Steve Brambley, CEO, GAMBICA commented: “Without public understanding, long-term support for sustainability strategies may weaken.” The ATUKI Summer 2025 Report, sponsored by Cadence Industrial & Technical Communications in partnership with Yonder Consulting, found that over two-thirds of the public (70%) believe the UK should increase its use of renewable energy. However, only 19% understand
NEWS 12 HYDRAULICS & PNEUMATICS October 2025 www.hpmag.co.uk what success looks like when it comes to national sustainability benchmarks. This highlights a pressing need for clearer, more accessible communication about both the consequences of climate change and how the G7 nations are responding. “We are stretching the limits of how much ecological damage we can get away with. It is now a quarter into the 21st century and we owe the planet at least 22 years of ecological regeneration, even if we stop any further damage now. If we still want to call this planet home, this level of overshoot calls for a scale of ambition in adaptation and mitigation that should dwarf any previous historical investments we have made, for the sake of our common future,” comments Dr. Lewis Akenji, board member of Global Footprint Network. Other key findings include: More than half (52%) believe individual sustainability actions contribute meaningfully to the UK’s overall sustainability progress. 51% believe electrification of cars and industrial processes is putting additional strain on the UK’s power grid. Only 3 in 10 consumers factor sustainability credentials into their purchasing decisions. Elaine Cobb, Senior Account Director at Cadence Industrial & Technical Communications, the report sponsor, said: “We have been measuring the general public’s perceptions on industry since 2013. The Summer 2025 ATUKI report shows that the UK public clearly wants to support a more sustainable future. And, we now know there’s a clear appetite for industrial leadership to share their sustainability stories. It’s time to broaden the conversation and show how UK industrial efforts contribute to global sustainability rankings. More than half the public believe individual action matters now more than ever, we must aim to gain consumer support with industrial-scale sustainability practices, whether that is supply chain knowledge or showcasing to the public the work that industry is undertaking.” The goal of ATUKI is to provide a snapshot of public perception of industrial impact and to help communicators within industry to consider the consumer in their plans to showcase industry achievements. The full report is available for download now: Reports – Attitudes to UK Industry The Attitudes to UK Industry (ATUKI) research initiative tracks public opinion on sustainability, innovation, and progress across UK industrial sectors. The 2025 Summer Report is based on a national survey of over 2000 respondents. EngineeringUK outlines success criteria for rollout of foundation apprenticeships Following the launch of foundation apprenticeships in England, EngineeringUK has published a new report - ‘Pathways to success: shaping foundation apprenticeships in engineering and technology’. The report makes a series of recommendations designed to ensure foundation apprenticeships have the potential to become a viable pathway into engineering and technology careers for young people. Foundation apprenticeships are intended to open up more training opportunities for young people – giving them a route into critical sectors while they earn and develop valuable skills. Their introduction seeks to reverse a worrying trend of declining recruitment onto level 2 apprenticeships. Beatrice Barleon, Head of Policy and Public Affairs at EngineeringUK, explained: “Addressing the shortages of engineers and technicians will be crucial in enabling the UK to prosper and grow. We therefore welcome the development of foundation apprenticeships and their aim of enabling more young people to access training in key sectors, including construction, and engineering and manufacturing. “However, we urge the government to be open to refining this new offer – to ensure they work for employers and young people alike. We hope our new report will help policymakers ensure the rollout of foundation apprenticeships is successful in addressing skills shortages across England.” ‘Pathways to success: shaping foundation apprenticeships in engineering and technology’ sets out 7 criteria for the government to consider. Drawing on insights from employers and education providers, the recommended success criteria for foundation apprenticeships are: Objectives are clear and complement other policies. Sectors with demand for level 2 foundation apprentices are identified. Employers buy in to the idea they are worthwhile. Small and medium-sized employers offer them. Standards are defined in a way that encourages high quality. Young people from a range of backgrounds are supported to succeed. They are financially viable for providers. Beatrice Barleon continued: “If foundation apprenticeships meet these criteria, it will ensure employers and young people have clarity on their purpose and will encourage uptake across businesses of all sizes. Crucially, it will also ensure providers are equipped to deliver the training and will maintain high quality standards. “We encourage the government to learn from the successes and shortcomings of previous programmes and build in evaluation, and if necessary, iteration, from the outset of the roll-out of foundation apprenticeships. “Government must work closely with industry to ensure that the skills system is responsive to employers’ needs. We look forward to continuing to facilitate these connections.”
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
HYDRAULICS When people talk about hydraulic failures, they often think first of pumps, valves, or hoses, but in many cases, the problem can be traced back to how a seal has dealt with pressure and load over time. Getting this right is less about dramatic breakdowns and more about consistent, careful design and material choice. Pressure is at the heart of how hydraulic systems work, and it’s also one of the main challenges for the seals that contain it. Each seal has to hold back the force generated by pressurised fluid without allowing leaks or deforming under stress. This sounds simple enough, but the relationship between pressure, temperature, movement, and material properties makes it a delicate balancing act. Too little pressure on the sealing surface, and the fluid escapes. Too much, and the seal can be squeezed, extruded, or even torn apart. When pressure rises above what the seal can handle, the material can begin to flow into any small clearances between metal parts. This is known as extrusion, and it’s a common reason for seal failure in high-pressure systems. Once a seal starts to extrude, it may lose its shape permanently, and the damage quickly leads to leaks. Designers often use backup rings -typically made from a harder material like nylon or PTFE - to support softer elastomer seals and stop them from being forced into gaps. It’s a simple measure, but one that makes a significant difference in the life of the seal. The load applied to a seal doesn’t come from pressure alone. It’s also affected by the mechanical forces within the system, such as side loading on a piston rod or uneven surface pressures caused by misalignment. These forces can cause the seal to wear unevenly or create areas where the sealing contact is too tight on one side and too loose on the other. Once wear begins, small leaks form, and pressure loss becomes gradual but steady. For this reason, understanding how components move under load—and how that movement transfers stress to the seal - is just as important as choosing the right material. Material selection is where many of the practical solutions lie. Each type of seal material reacts differently under pressure and load. Nitrile rubber (NBR) is widely used because it offers a good balance of flexibility and resistance to oil, but at very high pressures or elevated temperatures, it can start to lose its shape. Polyurethane, on the other hand, offers greater resistance to extrusion and can handle higher loads without deforming. PTFE seals are another option, especially for dynamic applications where friction and wear are major considerations. The right choice often depends on how pressure varies through the system - whether it’s steady, fluctuating, or prone to sudden spikes. Pressure cycling Pressure cycling is another subtle but important factor. Systems that regularly move between high and low pressure create repeated expansion and contraction of seals. Over time, this can lead to fatigue, particularly in softer materials. The seal might not fail suddenly but instead begin to seep slowly, requiring more frequent maintenance. To reduce this, designers sometimes choose seals with energising elements such as springs or pressure-activated lips that help maintain a consistent sealing force even as pressures change. Installation practices also play a part in how seals handle pressure. Even a wellchosen material can fail early if it’s nicked or stretched during fitting. A tiny cut on the edge of a seal might not be visible, but under pressure it becomes the 14 HYDRAULICS & PNEUMATICS October 2025 www.hpmag.co.uk When pressure tests the limits of a seal Even the best seal is only as strong as the pressure it’s designed to contain. Understanding how pressure and load interact helps prevent wear, leaks, and costly downtime. H&P reports. weak point where damage spreads. Using the right tools and lubricants during assembly helps avoid this, as does checking that metal edges are properly chamfered or deburred. It’s a small investment of time that prevents many early-life seal failures. For maintenance teams, monitoring pressure and knowing the limits of each component is essential. Running a system slightly above its rated pressure may seem harmless, but it accelerates wear across the whole hydraulic circuit. Over time, seals that were perfectly adequate for their original design pressure can begin to struggle. Pressure relief valves and accurate gauges are the best defences against this, as they keep the system within its safe working range. Ultimately, dealing with pressure and load in hydraulic seals isn’t about adding complexity, it’s about consistency and awareness. A well-matched seal, properly supported and installed, can handle demanding conditions for years without trouble. But even small oversights in material choice, hardware design, or operating pressure can shorten that life dramatically. The key is to approach sealing as part of the whole hydraulic system, not as an afterthought. When pressure, materials, and design all work together, seals stop being a weak link and become what they’re meant to be: reliable, invisible, and quietly doing their job.
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HYDRAULICS 16 HYDRAULICS & PNEUMATICS Octoberr 2025 www.hpmag.co.uk Roth Hydraulics expands internal machining capacity for piston accumulators Roth Hydraulics has significantly enhanced its capacity for the internal machining of piston accumulators. Through a comprehensive modification of an existing honing machine, the company can now process cylinder tubes with lengths of up to ten metres and diameters reaching 560 millimetres. “This will strengthen our vertical integration, improve quality assurance and increase production efficiency at the same time,” says Managing Director Frank Fuchs. Previously, the maximum workpiece length was five metres. With the new machine configuration, Roth Hydraulics has effectively doubled this capacity—a clear advantage for customers in the production of large cylinders and specialised applications. Honing the inner surfaces is one of the most decisive quality characteristics in the manufacture of piston accumulators. It exerts a crucial influence on functionality, service life, and the sealing performance of the accumulator. With the expanded machine, Roth Hydraulics ensures that this sensitive process step can now be carried out entirely in-house— independently, with assured quality, and with maximum flexibility. Another clear benefit: the honing work previously performed externally often resulted in extended cycle times and higher transport costs. By bringing this process inhouse, Roth Hydraulics now achieves significantly shorter throughput times while simultaneously reducing logistical expenses. This not only conserves resources but also supports the company’s broader sustainability objectives. The advanced honing machine features state-of-the-art control technology capable of automatically detecting shape deviations, such as bottlenecks, and adjusting the process accordingly. This guarantees a consistently uniform, highprecision internal surface—even for components with complex geometries. In addition, Roth Hydraulics continues to operate a second honing machine at the same site, which can be used in parallel to further enhance capacity and efficiency. Even after machining, the company’s quality standards remain uncompromisingly high: final inspections are conducted by trained specialists using precision measuring instruments, taking component temperature into account to ensure absolute accuracy and reliable results. “With this investment, we are offering our customers significant added value and also making an important contribution to greater sustainability in our processes,” emphasises Frank Fuchs. For further information please visit: www.roth-industries.de
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HYDRAULICS Ruland adds single beam couplings for light-duty precision systems Ruland has expanded its zero-backlash beam coupling line with the introduction of MI-series single beam couplings, complementing its existing one-, four-, and six-beam styles. Designed for lightduty applications with low torque requirements—such as encoders, tachometers, and small analytical devices—these new couplings provide engineers with greater flexibility in precision motion systems. Ruland’s single beam couplings feature a single helical cut that allows for greater angular and axial misalignment than comparable multiple-beam designs. This makes them particularly suitable for systems where precise alignment is difficult to maintain. Their compact geometry and low bearing loads help protect delicate system components, extending equipment life and improving overall system reliability. The MI-series is available in both clamp and set screw styles, with inch, metric, and inch-to-metric bore combinations ranging from 3/32 inch to 3/4 inch and 3 mm to 20 mm. All couplings have pure metric outer diameters and lengths to align with international design standards. In addition, hardware testing beyond DIN 912 12.9 standards ensures each coupling achieves maximum performance. With this addition, Ruland’s beam coupling line now offers outer diameters up to 50 mm, giving designers more freedom to select the ideal coupling configuration—single, four, or six beam— based on their specific performance, misalignment, and space requirements. Ruland single beam couplings are manufactured from high-grade 7075 aluminium bar stock sourced from North American mills, within the company’s ISO 9001:2015 certified advanced manufacturing facility in Marlborough, Massachusetts. All Ruland couplings are RoHS3, REACH, and Conflict Minerals compliant, underscoring the company’s commitment to quality and responsible manufacturing. For further information please visit: www.acorn-ind.co.uk/ruland Rotec Hydraulics has engineered a custom Hydraulic Power Unit (HPU) and Flushing Rig for a global F1 team, tackling the challenge of delivering safe, precise, and reliable pressure while ensuring optimal system longevity. Race car hydraulic systems demand meticulous maintenance, including regular flushing to prevent contamination - the primary cause of system failure. Traditional, bulky on-site equipment often leads to logistical issues and unwanted downtime. Rotec’s solution merges two critical functions into one compact, portable unit. The custom 3 kW HPU is designed to deliver 200 Bar of pressure at 8 Liters per Minute (LPM) to power race car hydraulic components. More crucially, it features an integrated flushing rig and particle counter, enabling technicians to maintain pristine oil cleanliness. A key differentiator is the integration of remote diagnostics via Parker IQAN technology. The HPU utilises Bluetooth connectivity to allow remote monitoring and control via a tablet or smartphone. This provides instant, detailed data on sensor and output states, including pressure, temperature, flow, and contamination levels. Jesse Cherry, Business Development Manager at Rotec Hydraulics commented: “This project showcases Rotec’s ability to deliver bespoke, highperformance hydraulic solutions that directly address challenges. We understood the critical need for a reliable, safe, and mobile solution. The integration of remote diagnostics streamlines operations and provides a great benefit to our client.” The dual functionality, combined with remote diagnostic capabilities, transforms maintenance from reactive repairs to proactive system health management. This compact, manoeuvrable rig minimises maintenance time, boosts operational efficiency, and significantly reduces the risk of critical hydraulic failures - a crucial competitive edge in the high-stakes world of Formula 1. For further information please visit: www.rotec.net Custom power unit brings precision and reliability to F1 maintenance The new lineup of Ruland beam couplings, including single beam 18 HYDRAULICS & PNEUMATICS October 2025 www.hpmag.co.uk
www.uschydraulics.com • 01555 772 474 • sales@uscltd.co.uk Scotland’s Independent Valve Stockist Pumps | Motors | Valves | Filtration Looking for a new career opportunity? Contact Andrew at DFA Media on 01732 370347 The simplest route to your next job H&P Recruitment filler.qxp_Layout 1 23/11/2015 12:40 Page 1 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
20 HYDRAULICS & PNEUMATICS October 2025 www.hpmag.co.uk 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. 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 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 demanding conditions. Importantly, they also Hydraulic hoses restore reliability to airport airbridges maintain their flexibility and minimum bend radius, which simplifies installation and enhances durability. The installations have demonstrated impressive performance with no leaks or defects, a result of Gates extensive research and development to create a seamless port-to-port solution. The hose and coupling combinations are designed to work seamlessly, offering trouble-free service throughout its working life, as Form-Plast’s experience confirms. “By using Gates MegaSys MegaTuff hose assemblies, we have resolved these unexpected issues, eliminating airbridge failures and ensuring that they remain operational for the six-year window, keeping operations running and reducing the airport operator’s maintenance costs in the long term,” concluded Held. For further information please visit: www.gates.com New generation of hydraulic pumps supports electrified systems Parker Hannifin has launched its new F1e and F12e hydraulic pumps, specially designed for variable speed drive applications. As the world increasingly turns towards electrification in the pursuit of a carbon-free future, Parker is at the forefront, leveraging its extensive experience and capabilities to facilitate this vital transition. Electrification plays a crucial role in reducing carbon emissions, and Parker’s eReady pumps are essential components in this journey. The F1e and F12e pumps offer highly efficient hydraulic control within a system, ensuring optimal performance in electric-driven applications. The technology behind the F1e and F12e pumps allows for a wide range of operating speeds, maximising the flow while lowering the torque. When paired with asynchronous or synchronous electric motors and controlled by
www.hpmag.co.uk HYDRAULICS & PNEUMATICS October 2025 21 frequency controllers, these pumps operate with exceptional efficiency and reliability, leading to significant energy savings. “The launch of the F1e and F12e hydraulic pumps marks a significant milestone in Parker’s commitment to driving the electrification of heavy-duty machinery,” said Fredrik Magnusson, Business Development Manager at Parker’s Pump & Motor Division Europe. “These pumps deliver exceptional efficiency and reliability across a wide range of operating conditions, enabling our customers to reduce emissions without compromising performance. By integrating advanced technologies that minimise energy loss and noise, we are helping to pave the way for a cleaner, quieter, and more sustainable future in hydraulic systems.” Parker’s F1e and F12e pumps represent a significant advancement towards more modern, efficient, and environmentally friendly hydraulic systems. These pumps are designed to integrate seamlessly with contemporary electric systems, including hybrid and fully electric vehicles. In addition to their efficiency, the F1e and F12e pumps are engineered to reduce pressure pulsation, which can cause vibrations that lead to unwanted noise in the hydraulic system. By reducing these pulsations, Parker enhances the overall performance and user experience of hydraulic systems, creating a quieter and more reliable solution. For more information please visit: https://ph.parker.com/gb/en/prod uct-list/bent-axis-fixed-eready-pumpsseries-f1e & https://ph.parker.com/gb/ en/product-list/bent-axis-fixed-ereadypumps-series-f12e Instant availability improves reliability of valve supply In response to industry concerns about global supply chain instability, as well as growing demand for their hydraulic products, Domin has launched an initiative that allows immediate shipping of their servo valve products, 75% faster than the industry average. With a new global distribution network and a simplified product range, Domin Valves are now immediately available, everywhere. Lead Time Zero guarantees instant global shipment to its core servo valve range; the S4 Pro, S6 Pro, and S10 Pro. Through a simplified product line and strategically stocked regional inventory, engineers, OEMs, and designers can now specify and receive high-performance Domin Valves, immediately. The initiative is designed to eliminate uncertainty and risk in servo valve procurement. By working closely with a global network of trusted partners, Domin ensures that its most in-demand valves are available exactly when and where they’re needed, across Europe, The America’s, and Asia. “In today’s uncertain environment, no one can afford to wait months for components,” said Marcus Pont, CEO of Domin. “Lead Time Zero addresses supply chain pressures by making our most widely used valves readily available, without compromising performance. It’s about giving OEMs, end users, and system integrators the confidence to design with more precision, speed, and performance, with less cost, energy, and wait times. Their critical systems can now keep running with access to rapid replacements.” Domin has also announced a simplified servo valve product range without compromising on performance. The S6 Pro has been enhanced to deliver the power density and dynamic control once reserved for their S6 Pro X. As a result, the S6 Pro X has been removed from the range, reducing range complexity, and making it easier for users to specify the right product with speed and confidence. The S6 Pro is the most widely adopted valve in the Domin portfolio, valued for its combination of power density, control accuracy, and size. It has become a central choice or customers in industrial, test, and automation environments. By standardising its portfolio and removing complexity, Domin has not only accelerated manufacturing but also made it easier for engineers to specify and deploy valves quickly, with confidence. Lead Time Zero enables a shift in how engineers and procurement teams can plan, specify, and deliver motion control systems. With dependable, short lead times, and often immediate dispatch, Domin helps customers avoid costly delays and reduce downtime risk. The upgraded S6 Pro simplifies the product selection process by replacing multiple variants with a single model that covers a broader range of performance requirements. Combined with global stock and local support, Domin is now positioned as a truly dependable supply partner, aimed at combining technical reliability with predictable supply. Domin’s new model challenges the accepted standard of the hydraulics market, where lead times of 12 to 16 weeks have long been accepted as inevitable. “That’s no longer good enough,” says Pont. “With Lead Time Zero, we’re proving that fast, reliable supply doesn’t have to come at the cost of performance.” Lead Time Zero is already operational. Throughout Domin’s distribution network there are valves in stock, shipping, and with customers with applications across test benches, timber processing, aerospace systems, and industrial manufacturing. For further information please visit: www.domin.com
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