www.hpmag.co.uk NOVEMBER/DECEMBER 2025 HYDRAULICS & PNEUMATICS VOL. 30 No. 8 NOVEMBER/DECEMBER 2025 p42 p28 Achieving true compatibility in electrohydraulic systems Countdown to Southern Manufacturing & Electronics 2026 Understanding valve demands in high pressure hydrogen systems p26 Electrifying industrial heating and the role of heat exchangers
The role of hydrogen in UK industry in 2026 EDITOR’S COMMENT www.hpmag.co.uk HYDRAULICS & PNEUMATICS November/December 2025 3 Experience gained during 2025 has reinforced a practical reality - without sustained investment in fluid power expertise, materials and manufacturing capability, ambitions for hydrogen risk outpacing the infrastructure needed to support them. ‘ ’ As we draw to the close of 2025, hydrogen is increasingly discussed as a pillar of the UK’s future energy system, yet the past year has shown how often the conversation underestimates the role of the industries required to make hydrogen workable at scale. Within that context, hydraulics and pneumatics underpin many of the systems on which hydrogen production, storage and distribution depend. Experience gained during 2025 has reinforced a practical reality - without sustained investment in fluid power expertise, materials and manufacturing capability, ambitions for hydrogen risk outpacing the infrastructure needed to support them. From electrolysis to compression, storage and distribution, hydrogen depends on the controlled movement of fluids under pressure, often in conditions that push existing system tolerances. These are environments where hydraulic and pneumatic technologies have long operated, but hydrogen introduces challenges that cannot be met by legacy solutions alone. High pressures, permeation risks and material degradation require deeper understanding of seals, valves, actuators and system integrity than many current designs were developed for. The UK fluid power sector has extensive experience in safety critical applications, including energy, process industries and heavy engineering. That experience is directly relevant, but relevance alone is not enough. Hydrogen demands adaptation, testing and redesign, particularly when it comes to materials compatibility, leak prevention and longterm reliability. These are not incremental changes. They require investment in research, skills and collaboration across supply chains. There is a risk that hydrogen infrastructure is approached with an assumption that existing components can be repurposed with minimal modification. That approach may reduce costs in the short term, but it increases long term risk. Failures in hydrogen systems will not be judged as isolated component issues but as systemic weaknesses. The performance of fluid power systems will be inseparable from perceptions of hydrogen safety and viability. At the same time, the direction of travel within hydraulics and pneumatics already aligns closely with hydrogen requirements. Greater use of sensors, condition monitoring and integrated control is becoming standard across the sector. In hydrogen applications these capabilities become essential rather than optional, enabling early fault detection, improved maintenance and safer operation. Investment in smarter fluid power is therefore not parallel to the hydrogen transition but part of it. Skills also require attention. As experienced engineers retire, the combination of fluid power knowledge and hydrogen awareness is scarce. Without deliberate investment in training and development, the UK risks relying on imported solutions rather than building domestic capability. That would represent a missed opportunity both economically and strategically. Hydrogen is often described as a technology of the future, yet the decisions that will determine its success are being taken now. For the hydraulics and pneumatics industry, this represents an opportunity to move beyond a purely supporting role and to be recognised as a core contributor to reliable hydrogen infrastructure. As the industry looks ahead to 2026, investment should follow that recognition, not as speculation, but as a practical requirement for systems that must operate safely, efficiently and at scale. I would like to thank our readers and advertisers for their continued support and wish them every success in the year ahead. Aaron Blutstein Editor
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www.hpmag.co.uk HYDRAULICS & PNEUMATICS November/December 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. 26 34 6 NEWS 16 HYDRAULICS Thermal management is increasingly central to hydraulic system performance as higher power densities raise operating temperatures. H&P reports. 26 PNEUMATICS As the use of hydrogen is increasing across the UK’s energymix, safely controlling its flow is vital to realise its potentialas a sustainable alternative. Tony Brennan explains. 28 INTEGRATED SYSTEMS Electro-hydraulic systems rely on precise interaction between electrical controls and hydraulic components. Ensuring full compatibility is essential for stable performance, accurate response and long-term reliability across varied industrial applications. H&P reports. 30 APPLICATIONS 34 KNOWLEDGE BASE 36 BFPA Hydraulics & Pneumatics’ issue-by-issue briefing on current activities and views involving the British Fluid Power Association. 38 COMPRESSED AIR, VACUUM, & GENERATORS 40 BCAS Our regular news and events update on the British Compressed Air Society. 42 SPECIAL REPORTS Southern Manufacturing & Electronics returns to Farnborough International Exhibition Centre from February 3–5, 2026, marking a major milestone - its 28th year as the South of England’s leading annual showcase for manufacturing and electronics innovation. H&P takes a closer look. 44 NEW FACES 47 PRODUCTS & SERVICES DIRECTORY 42 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 November/December 2025 www.hpmag.co.uk LAMMA 2026 returns to the NEC with focus on machinery, technology and sustainability LAMMA will return to the National Exhibition Centre (NEC), Birmingham, on 14–15 January 2026 as the UK’s largest exhibition dedicated to agricultural machinery, technology and engineering services. Marking its 43rd edition, the event maintains its position as the sector’s principal new-year meeting point, and its 2026 outing arrives at a time when agricultural engineering is facing rising cost pressures, heightened environmental expectations and rapid advances in digital and mechanical systems. Occupying 11 halls and hosting more than 600 exhibitors, the show will once again provide an unrivalled concentration of equipment, ranging from tractors and combines to cultivation systems, handling technologies, components, digital platforms and associated service providers. Its two-day format retains strong commercial influence; a significant proportion of attendees either hold purchasing authority or directly influence capital investment decisions, making LAMMA a critical showcase for product launches, model updates and technical demonstrations. A notable development for 2026 is the co-location of LAMMA with two established events: CropTec, focused on agronomy and crop technology, and the Low Carbon Agriculture Show, centred on sustainability, renewable energy and environmental business. All three will run concurrently within the NEC, with unrestricted access for visitors. This alignment reflects an industry in which engineering performance, agronomic decision-making and environmental outcomes are increasingly interconnected. Efficiency, cost reduction and emissions targets now depend as much on data, energy management and system integration as on mechanical capability alone. Low Carbon Agriculture will deliver structured conference content across three dedicated theatres, covering areas such as renewable power generation, carbon management, digital tools, policy updates and sustainable farming systems. CropTec will continue its established provision of technical insight for arable production. Although full programme details and speakers are yet to be confirmed, organisers have indicated that presentations, panel discussions and policy briefings will form a significant part of the offer, introducing a more formal knowledge and strategy component alongside the machinery exhibits. Despite the wider context, LAMMA’s core identity as a machinery-focused engineering showcase remains central. Exhibitors will range from global original equipment manufacturers to specialist independent firms, and the event continues to provide significant visibility for emerging or niche manufacturers seeking market access. The show will open at 08:00 on both days, closing at 18:00 on Wednesday and 16:30 on Thursday, with an early breakfast service from 07:00 to 09:00 for early attendees. Sustainability is expected to be a recurring theme across both the exhibition and the co-located conference programmes. Emissions reduction, energy efficiency, renewable energy generation and sustainable land management are now key determinants in machinery design, powertrain development and operational planning. The proximity of LAMMA to Low Carbon Agriculture underscores the extent to which net-zero objectives are influencing engineering investment and procurement strategies across the sector. As LAMMA approaches its fifth decade, its progression from a regional machinery event in Lincolnshire to a national platform for technology, innovation and strategic dialogue illustrates the transition underway within agricultural engineering. The move to the NEC has enabled continued growth and international reach, and the event remains a barometer of industry sentiment at the start of each year. For visitors in January, the machinery will remain the focal point, but the discussions surrounding it will increasingly address data, energy, policy and long-term resilience. LAMMA 2026 is therefore positioned not only as a showcase of equipment, but as an indicator of how engineering priorities are shifting as the sector adapts to new commercial and environmental realities. For further information please visit: https://www.lammashow.com UK manufacturers are losing up to £736 million every week due to unplanned downtime, according to new data released by Fluke Corporation. The findings highlight significant vulnerabilities in industrial resilience, with nearly seven in ten manufacturers reporting outages in the past year. Unplanned downtime costs UK manufacturers up to £736 million a week, survey finds
NEWS 8 HYDRAULICS & PNEUMATICS November/December 2025 www.hpmag.co.uk The research, conducted by Censuswide on behalf of Fluke, surveyed more than 600 senior decision-makers and maintenance professionals across the United States, the United Kingdom and Germany. It found that 68% of UK manufacturers suffered unplanned downtime in the past 12 months, revealing what Fluke describes as a “silent crisis” in operational reliability. The study shows that downtime is both frequent and prolonged. Nearly half (46%) of UK respondents reported between six and ten downtime incidents each week, while 15% said they experience 11 to 20 incidents weekly. In terms of duration, 45% said outages last up to 12 hours, and 17% reported incidents stretching to as long as 72 hours. At an average cost of £1.36 million per hour, a single incident could result in losses of up to £49 million – equivalent to powering 3900 factories for a week. While the frequency and duration of downtime are similar across the three countries surveyed, the cost impact is notably higher in the UK and Germany. In both markets, a single incident can cost up to £49 million, compared with a global average of £1.27 million per hour and £31.9 million per incident. The research indicates that downtime is a global operational challenge and a board-level risk to profitability and resilience. However, it also suggests that UK manufacturers face significantly higher costs than their US counterparts, pointing to what Fluke calls a critical gap in Europe’s industrial resilience. The problem is particularly acute among large enterprises. Globally, 40% of organisations with more than 50,000 employees reported experiencing between 11 and 20 downtime incidents each week, and half said these incidents lasted up to 72 hours. Despite the scale of the issue, Fluke’s findings show that the manufacturing sector’s response remains fragmented. UK manufacturers are distributing digital investments across several technologies aimed at improving resilience, including predictive maintenance (12%), digital twins (12%), and condition monitoring (13%). Parker Burke, Group President at Fluke, said: “Our research paints a sobering picture: manufacturers are caught in a cycle where downtime eats directly into competitiveness, and too many are stuck with fragmented fixes. “The data makes clear that the frequency, duration, and cost of downtime expose systemic vulnerabilities in maintenance and reliability strategies. What once was viewed as an operational inconvenience has become a risk to enterprise value. Without a clear path to scale digital investments, manufacturers’ efforts risk being spread too thin to deliver meaningful resilience or return.” He added: “The findings underscore the urgent need for manufacturers to rethink reliability not as a maintenance issue, but as a boardroom priority critical to growth, competitiveness, and customer trust.” S&A Academy, a leading UK training and apprenticeship provider, has issued a stark warning that the predicted business growth in the UK economy is at serious risk of “tanking”. The alert comes amid a perfect storm of severe skills shortages in artificial infrastructure services. The warning follows new projections from the International Monetary Fund (IMF), which recently stated that the UK is expected to be the second-fastest growing of the world’s most advanced economies this year. The IMF forecasts that in 2025 the UK economy will outperform other G7 nations apart from the US. However, it also predicts that the UK will experience the highest rate of inflation in the G7 in both 2025 and 2026. National apprenticeships and commercial training provider S&A Academy has cautioned that this economic optimism could be undermined by a growing digital transformation bottleneck. As more companies accelerate data integration and adopt AI and Generative AI technologies, the lack of qualified professionals has become a significant UK digital skills shortage could derail economic growth, warns training provider intelligence (AI) and data, set against the backdrop of rapidly developing digital transformation programmes across British businesses. The company warns that the shortage poses a serious threat not only to productivity and supply chains but also to national
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NEWS 10 HYDRAULICS & PNEUMATICS November/December 2025 www.hpmag.co.uk obstacle to progress. Sectors including insurance, finance, manufacturing, logistics and healthcare — where AI, data and automation are critical to future growth — are being heavily affected by the shortage of skilled professionals. The problem, the company argues, is being compounded by a lack of clear digital strategy and leadership at senior levels. Data, AI and Generative AI have advanced faster than traditional technology planning, while resistance to change, security concerns and outdated legacy systems have created further barriers to progress. S&A Academy, which provides bespoke training and apprenticeships in technology, data, science and business leadership, operates nationally across the UK. Its S&A Tech Academy achieved a 100% “achievement rate” for apprenticeship training last year and has launched a new suite of programmes aimed directly at addressing these skill shortages. Managing Director Jemma Perks commented: “We are facing a digital transformation crisis across the UK economy. The economic impact of skills shortages in the insurance, finance, manufacturing, logistics and healthcare sectors are happening now. We are currently seeing a real risk of operational disruption due to a lack of skills in these areas. This isn’t just a training issue; it’s a supply chain and productivity issue that affects British businesses and their consumers. “Demand for qualified and skilled professionals in tech, data and AI across insurance, finance, manufacturing, logistics and healthcare are outstripping the numbers of skilled professionals available. Across British companies there is a severe skills and talent shortage coupled with a resistance to change culture which is creating a perfect storm to throttle the British economy. “At the same time there is also strong demand for a newer generation of skilled professionals in data, tech and AI who can embrace change and transformation. This often means a ‘culture clash’ as established senior leaders in organisations are also reluctant to embrace change culture due to legacy systems, complex new technology and systems.” Digital transformation, Perks added, is as much about improving how businesses operate and make decisions as it is about adopting new technology. New Policy Centre launches to champion SME voices in UK manufacturing and engineering A new, independent Policy Centre, has been established to give the UK’s vast network of small and medium-sized enterprises (SMEs) in manufacturing and engineering a unified, influential voice in the corridors of power. More than 325,000 SMEs, in the engineering and manufacturing sectors, often supply chain businesses, are the backbone of the UK economy, driving innovation, job creation, and growth. Yet their experiences and insights have too often been overlooked in national policy discussions. The Policy Centre for Supply Chain and SME’s, Powered by Enginuity, the former Sector Skills Council,has been created to change that acting as a convener of industry leaders, sector bodies, policymakers, and government, ensuring that the realities facing British SMEs are not just heard, but drive meaningful change at the very highest level. The Centre’s mission is to engage SMEs directly, to unify and amplify their voices as an independent arbiter that brings together industry, industry bodies, policy organisations and government to collaborate on the skills and policy priorities that drive growth and support a thriving and resilient supply chain. Ahead of the budget, Ann Watson, CEO of Enginuity said: “SMEs are the lifeblood of the UK economy yet often fail to be heard by those making policy in key areas at the heart of government – and those honing policy need to listen. “Effective government policy depends on meaningful engagement with the people and organisations whose insights and experience are essential to its success. SMEs are huge in number but that can mean that they can be difficult to identify and engage and their individual voices lacks unification, amplification and clarity. “This is where Enginuity’s Policy Centre can really come in to its, own creating the epicentre between SMEs, Government and others, ensuring that positive and productive engagement and dialogue takes place.” The Policy Centre will work as a constructive ally and critical friend to the UK Government, supporting efforts to future-proof British manufacturing and engineering. By advocating for policies and skills development that reflect the real-world needs of SMEs, the Centre aims to help create a thriving, resilient industrial base that underpins the UK’s growth ambitions. Through advocacy, campaigns, and direct engagement, SMEs will have new opportunities to influence decisionmakers and see their input translated into tangible outcomes. The Centre will also provide clear guidance to help businesses navigate policy changes and contribute to evidence-led dialogue. This is a pivotal moment for UK manufacturing and engineering. With the launch of the Policy Centre, SMEs now have a powerful, united voice at the top table—ensuring their perspectives shape the future of British industry. Watson added: “By gathering robust data, conducting research, and fostering honest dialogue, the Policy Centre will provide evidence-based recommendations to shape policies that strengthen SMEs and reinforce the UK supply chain. We are here to do what’s right for SME’s and the supply chaingiving them a platform and the influence they deserve. “Our approach is collaborative and impact driven. We believe that by bringing together industry, sector networks, membership organisations, and large employers, we can align priorities, amplify influence, and tackle the sector’s most pressing challenges together.” Mike Reader, Labour MP for Northampton South, commented: “Congratulations to Enginuity for setting up the Policy Centre – it’s a big step forward, and I’m proud to be part of that journey with you. “I’m so pleased to see the Policy Centre is being launched to give SME’s a voice in how we develop the skills agenda and opportunities within our industry. Quite often SME’s don’t have that seat at the top table, the Policy Centre is going to provide that route to engage with government and make sure that the policies and outcomes delivered meet the broad SME needs.”
NEWS 12 HYDRAULICS & PNEUMATICS November/December 2025 www.hpmag.co.uk UK and Canada sign manufacturing pact to strengthen advanced technology collaboration Make UK has signed a trade and partnership agreement with Canadian Manufacturers & Exporters (CME), establishing a framework aimed at expanding industrial cooperation and trade between the two countries. The agreement, signed in Ottawa by Make UK Chief Executive Stephen Phipson and CME Chief Executive Dennis Darby, was witnessed by the UK’s High Commissioner to Canada, HE Rob Tinline, and Canada’s Minister of International Trade, The Hon. Maninder Sidhu. The partnership builds on a joint statement issued by the countries’ prime ministers in June and targets increased bilateral activity in areas regarded as strategically critical to both economies. These include rare earth minerals, nuclear technology and artificial intelligence, alongside a specific emphasis on defence and security collaboration, where both nations host established industrial capabilities. Beyond policy alignment, the organisations will cooperate on practical measures such as sharing information on science, technology and innovation, and promoting trade, investment and commercial exchanges among their member companies. Canada is currently the UK’s 16th-largest trading partner and 13th-largest export destination for goods, with bilateral trade worth £6.5bn annually. Phipson commented: “This is a welcome agreement which reflects the longstanding and, historic, relations between the UK and Canada on trade and other areas of co-operation. Make UK and CME have developed a strong relationship over many years, supporting the efforts of UK and Canadian manufacturers to invest, create jobs and develop supply chain connectivity. Today’s agreement will now look to make the most of this historic connection through this industry partnership to boost ties between manufacturers in both countries and support the ambition of both governments to increase investment and collaboration in vitally important technologies.” Darby added: “Canada and the United Kingdom have an opportunity to build one of the world’s most innovative and resilient industrial partnerships. Moving forward, we see real opportunities to deepen collaboration in advanced manufacturing, clean technology, and defence procurement. Canadian manufacturers are ready to lead alongside our UK partners, and we are eager for both governments to seize this moment for bold, forward-looking growth to support our sector.” The agreement is positioned by both organisations as a platform to enhance supply chain resilience, drive technology development and support long-term industrial competitiveness across key engineering-led sectors. The Manufacturing Technology Centre (MTC) has shared its response to the UK Government’s Post-16 Education and Skills White Paper, highlighting the potential benefits of the proposals for the country’s manufacturing sector. MTC said the plans could strengthen the industry’s long-term competitiveness by supporting high-quality reskilling and upskilling programmes and by establishing a national workforce strategy to ensure employers and workers can access “the right skills, at the right time.” According to the organisation, investment in skills and training remains essential to maintaining the global competitiveness of UK manufacturing and driving sustained economic growth. As technologies continue to evolve, MTC said, the UK workforce must be equipped to adopt and apply them effectively. The White Paper’s introduction of short, modular ‘Apprenticeship Units’, available through the reformed Growth and Skills Levy, was described by MTC as “a positive step” that could help manufacturers adapt to advanced technologies and improve productivity and profitability. MTC also welcomed the creation of three post-16 education pathways, saying they would offer “greater clarity, choice and opportunities for learners” while providing alternative routes into engineering and manufacturing. The organisation said this approach would help meet the changing needs of UK employers and encourage more people to pursue careers in the sector. The centre further noted that the proposed V-Levels represent an important step in simplifying vocational qualifications, reducing confusion in the system and helping industry engage more effectively with education providers. David Grailey, Managing Director, MTC Training, commented: “High quality reskilling and upskilling programmes – anchored in a national workforce strategy which uses Workforce Foresighting data and incentives – are needed to ensure employers and workers can invest in the right skills, at the right time. “The inclusion of short, modular ‘Apprenticeship Units’, accessible via the Levy, is a positive step that will help UK manufacturing adopt advanced technologies to drive competitiveness, productivity, and profitability. “We welcome the development of the three pathways for post-16 education as a step towards greater clarity, choice and opportunities for learners. These pathways will offer alternative routes of entry into engineering and manufacturing – helping to meet the evolving needs of UK employers and encourage more people into the industry. “The creation of V-Levels represents a significant milestone in streamlining the qualification landscape, reducing confusion, and increasing engagement with the education and skills system. As a critical sector for future growth and innovation, these proposals are good news for advanced manufacturing.” MTC welcomes Post-16 Education and Skills White Paper as boost for UK manufacturing
NEWS 14 HYDRAULICS & PNEUMATICS November/December 2025 www.hpmag.co.uk Combilift re-qualifies for Deloitte Best Managed Companies Award for 13th consecutive year Irish manufacturer Combilift has been recognised once again as one of Ireland’s Best Managed Companies by Deloitte, marking its 13th consecutive year receiving the distinction. The recognition follows a detailed requalification process designed to assess organisations across four key performance areas: strategy, culture and commitment, capabilities and innovation, and governance and financials. The process requires previous awardees to demonstrate continued excellence and leadership in a changing global business environment. According to Deloitte, the programme identifies companies that show sustained strategic focus and operational effectiveness over time. “The renowned Deloitte international brand Best Managed Companies programme sets a high benchmark, and requalifying for the 13th time reinforces our position as a serious global business,” said Martin McVicar. “While we’re known for manufacturing innovative world-class material handling solutions, this recognition also speaks to how we run our business — from our lean operations and customer-focused R&D to our worldclass production facility in Monaghan.” Combilift, founded in Monaghan in 1998, has grown into a major global producer of multidirectional forklifts and material handling solutions. The company’s continued presence on the Best Managed Companies list reflects its long-term focus on innovation, efficiency, and strategic management. Deloitte’s programme is part of a global network recognising private companies that demonstrate strong business performance and organisational culture. Combilift’s requalification underscores its ability to maintain high standards of governance and performance across multiple business cycles. Grow your reach with connections from our qualified global database machines&factories E-campaign | List Rental | Lease | Lead Generation Damien Oxlee T: +44 (0)1732 370342 E: damien.oxlee@dfamedia.co.uk
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HYDRAULICS In hydraulic engineering, pressure and flow often dominate discussion, yet thermal management plays an equally influential role in determining system efficiency and operational life. As hydraulic systems become smaller and more powerful, engineers are placing increasing emphasis on managing the heat generated during operation. Thermal load in hydraulic circuits arises from fluid friction, component inefficiencies and pressure losses. When this heat is not effectively dissipated, fluid degradation accelerates, lubrication becomes less effective and components such as seals, hoses, pumps and valves experience higher rates of wear. Even moderate increases in temperature can affect energy consumption and undermine long-term reliability, making controlled operating temperatures essential. Heat exchangers Heat exchangers provide the primary means of managing this thermal load. Air-cooled units are widely used in both mobile and industrial settings, particularly where water is unavailable or unsuitable. Their compact design and ease of installation make them a practical choice across a broad range of applications. Water-cooled heat exchangers, offering higher thermal efficiency, tend to be adopted in environments with a stable water supply and more stringent cooling requirements. Manufacturers such as Emmegi Heat Exchangers UK continue to refine exchanger design to balance durability, performance and ease of integration with increasingly complex hydraulic systems. Selecting an appropriate cooling solution requires consideration of the system’s fluid characteristics, its environmental conditions, available installation space and the desired operating temperature range. Incorrect sizing or selection can restrict performance or raise energy use, prompting many engineers to incorporate thermal planning earlier in the design process to ensure a suitable match between system and cooling equipment. The impact of appropriate thermal management is evident in operational settings. In one recent case, a customer of Emmegi using heavy-duty machinery in a high-temperature environment reported recurring hydraulic failures linked to insufficient heat dissipation. After replacing the existing unit with an Emmegi air–oil heat exchanger designed to improve airflow and fin efficiency, the operator recorded a 40% reduction in downtime and a significant increase in hydraulic fluid lifespan. This example 16 HYDRAULICS & PNEUMATICS November/December 2025 www.hpmag.co.uk The importance of thermal management in hydraulic systems Thermal management is increasingly central to hydraulic system performance as higher power densities raise operating temperatures. Effective cooling safeguards component life, improves efficiency and supports reliability across demanding applications today. H&P reports. illustrates how targeted cooling solutions can address persistent reliability issues. Heat control As electrification, automation and compact system architectures continue to influence the fluid power sector, thermal management is expected to play an even more critical role. Developments in compact exchanger design, embedded sensor technologies and predictive maintenance are already shaping a more data-driven approach to heat control. Thermal management is now recognised not merely as a measure to prevent overheating, but as a determinant of hydraulic system performance, efficiency and longevity. As industry demands evolve, effective temperature control is likely to become an increasingly central component of system design and engineering practice. For further information please visit: www.emmegi.co.uk
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HYDRAULICS When discussing the behaviour of hydraulic piston rods, Mattias Awad begins by stressing the importance of surface protection. A thin layer of chrome or nickel chrome has long been relied upon to deliver low friction, wear resistance and corrosion protection. However, he notes that this protective layer only performs as expected if the underlying steel maintains very consistent quality. Because Ovako Cromax controls production from the steel mill through to final plating, the company can maintain the tight tolerances needed to achieve consistent coating results. In many applications a hard chrome layer on its own is sufficient. In more demanding environments such as mining, offshore equipment or chemical processing plants, manufacturers often add a nickel underlayer. Awad explains that this layer significantly improves corrosion resistance by preventing pitting and slowing the penetration of corrosion into the steel, even when lubrication is disturbed or surface damage occurs. Traditionally the top layer in these duplex systems has been hexavalent chrome. Although this material has performed well for decades, it is subject to strict controls under the REACH regulation. Combined with growing customer interest in sustainability, this led Ovako Cromax to pursue an alternative. NiKrom III is the result. It retains the established nickel underlayer but replaces the hexavalent chrome with a hard trivalent chrome surface. Developing the NiKrom III process Awad explains that shifting to CrIII required a significant research effort. The chemical behaviour of trivalent chrome is more sensitive than that of hexavalent chrome, and maintaining stability in the plating bath requires strict control. Ovako Cromax worked with a major chemical supplier and relied heavily on its own experience in duplex coatings to establish a process that could deliver the same level of corrosion resistance as the existing NiKrom products. The first demonstrator rods were produced in 2017 at the company’s facility in Redon, France. These initial samples were produced on a manually operated pilot line. Since then the process has been refined, and a pre-series production line is now in operation. It can coat bars up to 3 metres in length and with diameters from 20 to 140 millimetres. A key requirement during development was that NiKrom III should work with existing hydraulic cylinder designs. According to Awad, the coating needed to match the hardness, surface structure and friction characteristics of conventional chromium coatings so that sealing systems and mechanical interfaces would not need to be redesigned. This compatibility has been achieved. NiKrom III can also be applied to any Ovako Cromax steel grade without additional heat treatment, so established mechanical 18 HYDRAULICS & PNEUMATICS November/December 2025 www.hpmag.co.uk A new sustainable coating for hydraulic piston rods As hydraulic systems move into more corrosive, demanding and environmentally regulated conditions, surface technology is becoming a central design consideration. H&P spoke to Mattias Awad, Head of Marketing and Technology at Ovako Cromax, to discuss the company’s development of NiKrom III, a new CrVI-free duplex coating. He explained how the technology was created, why it addresses the industry’s sustainability challenges and what early field trials with Sandvik Mining and Rock Solutions reveal about its performance. properties and fatigue behaviour are preserved. These attributes make NiKrom III suitable for heavy duty environments, but also for exposed applications that remain in service for long periods. Examples include snow ploughs, tailgate lifts and ski lift systems. Figure 1 shows a typical application on a Sandvik loader. Field performance One of the earliest adopters of the new coating has been Sandvik Mining and Rock Solutions. The company operates in some of the harshest industrial environments and has placed increasing emphasis on machine reliability as automation and remote monitoring become more widely used. Sandvik also has Science Based Targets initiative validated sustainability goals which include a 50 per cent reduction in scope 1 and 2 greenhouse gas emissions and a 30 per cent reduction in scope 3 emissions by 2030. After an introduction by Ovako NiKrom III lift cylinder rods on a Sandvik loader operating in harsh mining conditions.
www.hpmag.co.uk HYDRAULICS & PNEUMATICS November/December 2025 19 www.tom-parker.co.uk sales@tom-parker.co.uk 01772 255109 Since 1972, Tom Parker Ltd has been the UK’s premier independent distributor of 昀uid power solutions, BSI ISO 9001:2015 certi昀ed and BFPA-a昀iliated. Our new 2026–27 catalogue is your comprehensive guide to over 30,000 products from 70+ global brands, powering pneumatic, hydraulic, process, and industrial applications. Exciting New Brands & Innovations We’ve expanded with additions to keep your operations ahead: ! " # $%$& ' " Your One-Stop Fluid Power Shop Powering Your Success NEW Cromax’s partner Wipro Infrastructure Oy, technical teams from Sandvik and Ovako Cromax began evaluating the coating. This led to in field testing in copper mines where saline atmospheres create very aggressive corrosion conditions. In these trials standard cylinders typically began to show corrosion after a period in service. NiKrom III treated cylinders remained corrosion free for up to five times longer. Figure 2 illustrates this comparison. To date around 20 Sandvik machines have been equipped with NiKrom III cylinders. Further deliveries are planned during 2025 and the coating is now offered as an option on selected Sandvik cylinder types. Wider sustainability framework NiKrom III supports Ovako Cromax’s broader sustainability programme. The company monitors the carbon footprint of each stage of production including steelmaking, hot rolling, transport, machining and plating. The resulting product has a carbon footprint that is 80 per cent lower than the global average. Full carbon footprint data can be supplied to customers who require it for their own lifecycle assessments. Preparing for future requirements Awad notes that many industries are moving rapidly toward CrVI free materials, not only because of legislation but because equipment operators are demanding longer service life in ever harsher conditions. NiKrom III has been developed to meet these expectations. It offers a direct alternative to CrVI coatings while maintaining performance and compatibility with established hydraulic designs. As sectors such as mining, marine operations, wind energy and coastal infrastructure continue to develop, coatings that combine durability with environmental compliance will play an increasingly important role. NiKrom III is positioned to support that transition, providing a practical and field proven solution that meets both operational and sustainability needs. Comparison of hexavalent chrome and NiKrom III in the salt laden environment of a copper mine. Left: a standard CrVI coated rod showing degradation before the end of its service life. Right: a NiKrom III coated rod showing no visible corrosion after more than five times longer in service.
HYDRAULICS Industrial heat demand accounts for more than 20% of global energy consumption?. Decarbonising this heat is essential to achieving net-zero targets, and the electrification of a wide range of processes and equipment, from space heating to furnaces, is one of the most practical ways to do it. Electrification can also deliver benefits such as improved energy efficiency and lower operating costs?. Industrial heat demand and decarbonisation According to Matt Hale, Global Key Account Director at HRS Heat Exchangers, industrial heat represents a significant share of global energy use, making its decarbonisation a crucial part of the transition to net zero. Electrifying heating processes offers one of the most effective ways to reduce emissions while improving efficiency and cost control. However, the shift to electricity is not without challenges. Hale notes that economic factors, technical limitations, a lack of knowledge, and infrastructure constraints continue to slow progress?. The scale of industrial heat use makes the task even more complex. Industry consumes around 37% of total global energy, two-thirds of which is used for heat generation. Of that, around 80% is still produced by burning fossil fuels?. Research from McKinsey & Company? highlights that manufacturing, food and beverage, and agriculture and forestry are the sectors most dependent on processes requiring lowtemperature heat (below 200 °C). Manufacturing and food and beverage could see the greatest benefits from electrification in the near term, with potential electrification rates of 62% and 44% of total energy demand respectively by 2030. Technologies for the electrification of heat Hale explains that choosing the best technology for electrical heating depends on the temperature required, the holding time, and the process capacity. Established technologies such as mechanical vapour recompression (MVR) and heat pumps can cover a wide temperature range, from 50 °C to over 200 °C. Newer technologies, including e-boilers and turbo heaters, are now reaching commercial maturity and can provide heat up to 500 °C and 1000 °C. Rapid progress is also being made with induction heating, which is increasingly suitable for higher-temperature industrial applications. The speed of heating is another important consideration, and in this respect e-boilers typically respond faster than heat pumps. According to Hale, the market has yet to settle on definitive technological winners, with broad commercial maturity not expected before 2030. Even so, some technologies, such as MVR and ohmic heating, are already proven and are being applied by HRS Heat Exchangers in suitable projects. Ohmic heating Hale highlights ohmic heating as an effective example of how electricity can be used to provide precise and uniform heating. In fruit juice pasteurisation, for instance, the technique has been shown to inactivate bacteria, yeast, and moulds efficiently while maintaining the natural flavour and quality of the product. The HRS Ohmic System passes an electric current between two electrodes as the juice flows through a one-metre ceramic tube. This heats the juice to 105 °C in one second, holds it at that temperature for four seconds, and then cools it. Although ohmic heating is not a new concept, the HRS design uses advanced electronic controls to deliver a very smooth temperature curve, improving both product quality and process efficiency. While the equipment represents a higher capital cost than traditional pasteurisation, and running costs depend on electricity prices, Hale notes that more processors are turning to the technology because of its proven benefits. The ability to produce ‘as fresh’ juice with better taste and shelf life allows many to sell into premium markets, making the investment worthwhile. Mechanical vapour recompression (MVR) Hale also reports growing interest in MVR technology for evaporation, particularly following the volatility of energy 20 HYDRAULICS & PNEUMATICS November/December 2025 www.hpmag.co.uk Electrifying industrial heating and the role of heat exchangers Industrial heating systems depend on precise control of fluid flow and heat transfer. As electrification reshapes energy use, H&P looks at how technologies such as mechanical vapour recompression and ohmic heating are improving hydraulic performance, energy efficiency, and sustainability across industrial processes.
www.hpmag.co.uk HYDRAULICS & PNEUMATICS November/December 2025 21 STAINLESS STEEL HYDRAULIC HOSE AND PIPE FITTING SPECIALISTS We are the leading manufacturer and stockist of stainless steel hose fittings, tube fittings and adaptors. Call one of our friendly and knowledgeable specialists today to see how we can help. 30 TRADING FOR OVER YEARS CALL 01274 852 066 sales@customfittings.com www.customfittings.com PROUDLY MADE IN THE UK markets in recent years. MVR systems use electrical energy, which is often less expensive than the thermal energy required for conventional evaporation. Traditional evaporators rely on high-temperature service fluids such as pressurised steam to heat a product above its boiling point. The steam is typically produced by burning fossil fuels. In an MVR system, the steam that is generated from the product is captured and compressed, which increases its pressure and temperature. This recompressed steam is then reused as the heating medium. Because the compressor is powered by an electric motor, the process runs on electricity rather than combustion. By reusing the evaporated steam, MVR systems recover a large amount of latent heat, making them one of the most energy-efficient and cost-effective evaporation methods available. However, Hale advises that MVR is not always the best option for every process. The type of product or waste stream being evaporated can affect performance, so both capital and operating costs must be carefully assessed before selecting a system. Matt Hale concludes that the electrification of industrial heating is both a challenge and an opportunity for process industries. Technologies such as ohmic heating and MVR demonstrate that electricity can provide reliable, efficient, and sustainable heat for industrial applications. As electrification continues to advance, these technologies will help drive down emissions, improve efficiency, and support the transition to a low-carbon industrial future. References 1. McKinsey & Company: Tackling heat electrification to decarbonize industry. https://www.mckinsey.com/industries/industrials-andelectronics/our-insights/tackling-heat-electrification-to-decarbonizeindustry 2. Rosenow, J. et al. The heat is on: Policy solutions for industrial electrification. https://www.sciencedirect.com/science/article/pii/ S2214629625003081 MVR is one of the cheapest methods of evaporating water in terms of operational costs
HYDRAULICS Hydraulic power remains integral to many parts of the UK industrial economy. From metal processing and component testing to rail maintenance and waste management, most sectors rely on hydraulic actuation in some form. These systems are built for strength, yet their reliability often hinges on an invisible variable: the cleanliness of the fluid circulating inside them. As machinery becomes more precise and maintenance budgets face closer scrutiny, contamination control is moving from a secondary maintenance concern to a central measure of system health. Clean hydraulic oil is not just a matter of appearance. It determines how effectively pumps, valves, and actuators perform under load, and how long they last before repair or replacement. In practice, maintaining cleanliness is difficult. Systems breathe, seals degrade, and temperature changes draw in moisture. Microscopic debris from component wear recirculates until removed. Once particle levels rise beyond recommended limits, wear accelerates and efficiency drops. Over time, small contamination issues become the root cause of breakdowns that appear mechanical in nature. Across UK industry, the demand for finer control and higher energy efficiency is making this issue harder to ignore. Modern proportional valves and servo systems operate with extremely close clearances, meaning the size of an acceptable contaminant is smaller than a human hair by several orders of magnitude. Hydraulic components that would have tolerated moderate contamination twenty years ago now fail quickly under the same conditions. At the same time, energy costs are pushing operators to maintain fluids at optimum viscosity and cleanliness, reducing losses caused by friction and internal leakage. The conversation around filtration has matured in response. Most engineers now recognise that the choice of filter is only part of the solution. What matters equally is where filtration occurs, how it is monitored, and whether the results are verified through fluid analysis. Typical cleanliness targets, expressed using the ISO 4406 code, are between 18/16/13 for standard industrial systems and 15/13/10 for more sensitive ones. Achieving and maintaining these levels consistently requires careful sizing of filters, correct flow paths, and regular checking of pressure differential across elements to prevent bypass. UK suppliers and service companies are adapting to this change. Instead of focusing purely on hardware, many now provide system assessments and cleanliness management programmes. These include return-line filtration upgrades, dedicated offline “kidney loop” systems, and moisture control devices designed for the country’s variable climate. Condensation and airborne moisture remain persistent issues in outdoor or unheated environments, particularly in construction and materials handling. Water contamination accelerates oxidation, corrodes internal surfaces, and breaks down fluid additives, so desiccant breathers and waterabsorbing filters are becoming routine features in many installations. Air ingress is another growing concern. Entrained air changes the compressibility of the fluid and can cause erratic actuator 22 HYDRAULICS & PNEUMATICS November/December 2025 www.hpmag.co.uk Why fluid cleanliness is defining hydraulic reliability As operating margins tighten and expectations of reliability increase, managing fluid cleanliness has become one of the most practical ways to reduce failure risk and extend equipment life. H&P reports. movement or cavitation. The combined effect of air, water, and particulate contamination can be subtle but is cumulative. Addressing them requires a consistent approach rather than reactive maintenance when problems appear. Fluid analysis complements this approach. While filters manage contamination, analysis verifies that they are working and highlights issues before they affect performance. Periodic sampling, typically every few hundred operating hours, provides information on particle counts, moisture content, viscosity, and chemical degradation. UK laboratories now offer rapid analysis services, often including trend graphs that show whether contamination is stable, increasing, or declining. Maintenance teams can then schedule filter changes or system inspections based on actual condition rather than fixed intervals. This shift to data-driven maintenance is particularly valuable where machinery operates continuously or is difficult to access. Integrating filtration and analysis For operators, the practical challenge is integrating filtration and analysis into daily routines. Both depend on disciplined
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