www.hpmag.co.uk JUNE 2026 HYDRAULICS & PNEUMATICS VOL. 31 No. 4 JUNE 2026 p28 p38 Questioning old assumptions in electropneumatic design Driving consistency through precision fluid metering The rise of variable speed hydraulics p26 The hidden factors behind compressed air dryer selection
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Manufacturing needs consistency EDITOR’S COMMENT www.hpmag.co.uk HYDRAULICS & PNEUMATICS June 2026 3 The next Prime Minister will inherit an economy where improving productivity, strengthening domestic manufacturing and increasing resilience across supply chains remain pressing priorities. ‘ ’ The Prime Minister’s announcement that he intends to resign has, unsurprisingly, dominated the political conversation. For those of us involved in manufacturing, however, the more important issue is not who succeeds him, but whether another change in leadership results in yet another reset of Britain’s industrial priorities. Engineering businesses do not plan in electoral cycles, and investment in production facilities, automation, skilled people and research is measured over years, often decades. Whether developing new hydraulic systems for mobile machinery, investing in advanced pneumatic technologies for factory automation, or expanding manufacturing capacity to meet growing demand, companies need confidence that the policy environment will remain broadly consistent throughout the life of those investments. This matters because the fluid power sector sits at the centre of much of the UK’s industrial economy. Hydraulic and pneumatic technologies enable manufacturing, construction, infrastructure, defence, energy, agriculture and logistics. They are integral to the machinery that builds homes, supports renewable energy projects, keeps production lines moving and underpins critical national infrastructure. Yet the sector rarely receives the attention it deserves when industrial policy is debated. The next Prime Minister will inherit an economy where improving productivity, strengthening domestic manufacturing and increasing resilience across supply chains remain pressing priorities. Delivering on those ambitions will depend not only on headline investment announcements, but on creating the conditions that encourage businesses to invest their own capital with confidence. For our industry several issues are key including energy costs which continue to affect the competitiveness of UK manufacturers. Skills shortages remain a constraint on growth, particularly in engineering and technical disciplines. Investment in automation and digital manufacturing is accelerating, while demand is increasing for more efficient hydraulic and pneumatic systems that support both productivity and sustainability. At the same time, opportunities in defence, infrastructure and the energy transition present significant growth potential for businesses across the fluid power supply chain. These are not challenges that can be addressed through short-term initiatives or successive rebranding of industrial policy. They require consistency of purpose and meaningful engagement with the manufacturers, distributors, system integrators and engineering specialists responsible for delivering the technologies on which modern industry depends. The UK has no shortage of engineering capability and British companies continue to innovate, export and compete successfully in demanding global markets. What is less certain is whether government can provide a stable framework that matches the timescales on which manufacturing businesses operate. Political leadership will inevitably change but industrial strategy should not. As Westminster begins another period of transition, our sector will be looking beyond personalities and party politics. The measure of the next government will not be the speed with which it announces new initiatives, but whether it can maintain a clear and consistent direction for British manufacturing. Businesses are ready to invest, innovate and grow, but they need confidence that the rules of the game will not change every time the political landscape does. Aaron Blutstein Editor
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www.hpmag.co.uk HYDRAULICS & PNEUMATICS June 2026 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. 16 28 6 NEWS 16 HYDRAULICS 24 PNEUMATICS 26 INTEGRATED SYSTEMS Rising energy costs, tighter sustainability targets and growing demand for smarter industrial equipment are accelerating the adoption of variable speed drive technology in hydraulics. H&P’s Aaron Blutstein spoke to Juraj Bittner, Product Manager, Industrial Solutions at Danfoss Power Solutions, about how changing attitudes towards efficiency, electrification and machine control are driving a new generation of hydraulic architectures. 28 APPLICATIONS Rising energy costs and greater scrutiny of operating expenditure are encouraging manufacturers to challenge long-held assumptions about compressed air systems. What was once viewed primarily as a maintenance concern is increasingly influencing specification decisions, procurement strategies and the way electro-pneumatic performance is assessed throughout the life of an asset. 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, VACUUM, & GENERATORS Louis Cottaz, Product Manager at Donaldson, looks at hidden factors when choosing the right compressed air dryer. 36 BCAS Our regular news and events update on the British Compressed Air Society. 38 SPECIAL REPORTS 46 NEW FACES 47 PRODUCTS & SERVICES DIRECTORY 38 Subscribe for your FREE copy now Printer: Warners, UK © Copyright 2026, 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 June 2026 www.hpmag.co.uk Report finds manufacturers risk AI productivity gains without urgent action on skills and adoption A new Make UK report has revealed that while AI could unlock billions in productivity gains for UK manufacturing, skills shortages and low levels of adoption risk preventing businesses from realising its full potential. The report, AI, Skills and the Future of the UK Manufacturing Sector, highlights how AI technologies are already helping manufacturers improve efficiency, productivity and resilience, but warns that most firms remain stuck in the early stages of adoption. Despite growing awareness of AI’s potential, only 2% of manufacturers say AI is widely embedded across their operations. Just under 40% are using AI in some departments, while nearly one in five have not adopted AI at all. The findings come at a critical moment for UK industry. Make UK estimates the manufacturing sector loses around £6 billion in output each year due to unfilled vacancies and digital capability gaps, while wider digitalisation across the sector could unlock a £150 billion boost to UK GDP by 2035. However, the report warns that many firms lack the skills and organisational readiness needed to move from smallscale AI trials to full business transformation. Currently, AI use is concentrated in back-office functions, with 83% of manufacturers using tools in areas such as HR, finance and administration. Adoption in core operational areas remains far lower, with only 11% using AI in production, 7% in supply chain and logistics, and 6% in quality control. The report also finds that AI’s impact on jobs remains limited for now. So far, AI has mainly been used to automate repetitive administrative tasks rather than replace workers or fundamentally redesign roles. However, nearly half of manufacturers expect AI to reshape jobs and ways of working within the next two years. Rather than eliminating jobs, the report suggests AI is more likely to augment existing roles and create demand for hybrid skills. Examples already emerging include maintenance engineers using predictive analytics, planners using AI-assisted scheduling tools and quality inspectors shifting from manual checks to exception management. Skills shortages are identified as the biggest barrier preventing manufacturers from adopting AI more effectively. More than half of manufacturers say capability gaps are their main obstacle, particularly at technician and operator level. The report found manufacturers are prioritising practical skills such as data literacy, problem solving, leadership and change management over specialist coding expertise. However, half of businesses say staff do not have time to train, while many remain unclear about what good AI skills look like for manufacturing roles. To address these barriers, and to support the ambitions of the UK’s Modern Industrial Strategy for a more productive, competitive and technology-enabled manufacturing base, Make UK is calling for: Nationally recognised AI skills standards for manufacturing roles Greater practical support for SMEs adopting AI, so smaller manufacturers can move from experimentation to implementation Flexible, shift-friendly training that works in factory environments Responsible, workforce-centred AI adoption that builds confidence and supports job quality Stronger support through programmes such as Made Smarter, alongside clear sector leadership to help manufacturers adopt AI at scale A strong role for the Advanced Manufacturing AI Champion in helping translate national ambition into practical action, convening industry and government, identifying barriers to adoption and accelerating the spread of proven use cases across the sector The report calls for education and training providers to deliver more practical, manufacturing-focused AI training aligned with real industrial use cases. Make UK will also expand its work through a new AI Skills & Adoption Working Group with government and industry partners to develop guidance, tools and case studies. It concludes that AI could significantly boost UK manufacturing productivity and competitiveness, but only if firms are supported to move from experimentation to implementation. Nina Gryf, Senior Policy Manager – AI & Digitalisation, Make UK commend: “AI has huge potential to improve productivity, efficiency and resilience across UK manufacturing, but our research shows that many businesses are still at the experimentation stage and have yet to embed these technologies at scale. While manufacturers recognise the opportunities AI presents, too many are being held back by skills shortages, limited capacity for training and a lack of practical support…If we are to realise the full economic benefits of AI and strengthen the competitiveness of UK industry, government, industry and education providers must work together to support widespread adoption.”
NEWS 8 HYDRAULICS & PNEUMATICS June 2026 www.hpmag.co.uk Rockwell Automation announces new research showing UK manufacturers shift from AI adoption to industrial execution Rockwell Automation has announced the UK findings of its 11th annual State of Smart Manufacturing Report. The study, based on feedback from more than 1500 manufacturing leaders globally, highlights a clear shift in how UK manufacturers are approaching digital transformation. With 87% of organisations now recognising it as essential and allocating an average of 27% of operating budgets to industrial technology, the UK has moved beyond early-stage adoption and into a phase where digital investment must translate into operational performance. “UK manufacturers are moving beyond experimentation into a phase where digital technologies must deliver consistent operational outcomes,” said Phil Hadfield, UK managing director, Rockwell Automation. “The challenge is no longer access to technology, but the ability to embed it into production environments in a way that improves performance, resilience and competitiveness.” Artificial intelligence sits at the centre of this transition. Nearly half of manufacturers have already invested in AI, and adoption of generative AI is now widespread. The focus, however, is shifting away from experimentation toward practical use cases that deliver measurable value. Cybersecurity has emerged as the leading AI application, followed closely by quality control and process optimisation, reflecting a growing emphasis on protecting and stabilising increasingly complex production environments. This growing reliance on connected technologies is also reshaping risk. Half of UK manufacturers report experiencing at least one cyberattack in the past year, despite strong levels of investment in cybersecurity. The implication is clear: as digital maturity increases, so too does exposure. Cybersecurity is no longer a supporting function, but a central pillar of industrial strategy. At the same time, workforce dynamics are becoming a defining factor in how quickly digital transformation can progress. Rising labour costs now affect 40% of manufacturers, while change management challenges have increased significantly year-on-year. Rather than reducing headcount, organizations are focusing on reskilling and workforce development, with more than a third of employees now engaged in training programmes designed to support digital roles. This shift is closely linked to the growing importance of AI capability. A clear majority of manufacturers now see AI skills as critical to attracting the next generation of talent, highlighting a structural change in how industrial workforces are being shaped. Alongside AI, simulation technologies such as digital twins are beginning to move from concept to deployment. While just over a quarter of manufacturers having already implemented these technologies, the vast majority are either investing or planning to do so, signalling strong forward momentum. These tools are enabling organisations to test scenarios, optimize processes and reduce operational risk before making changes on the factory floor. However, the full value of these technologies is being constrained by a more fundamental issue: data. UK Flowfit celebrates 30 years in business Hydraulic components and systems supplier Flowfit is celebrating its 30th anniversary, marking three decades of growth, innovation and customer partnerships since the company was founded. The business officially began its anniversary celebrations on 1 June, marking 30 years of growth, innovation and customer partnerships. The milestone follows another significant development for the company, which joined Axel Johnson International in December 2025. Flowfit said the move creates new opportunities for employees, customers and suppliers as the company enters its next phase of development. “Reaching this milestone is a testament to the hard work and dedication of our team, and to the loyalty and support of our customers and partners over the years,” said managing director Simon Parsonage. Flowfit said the Anniversary provides an opportunity to thank everyone who has been part of its journey over the past 30 years and to recognise the contribution of customers, partners and employees to the company’s success. Looking ahead, the business said it is focused on building on its recent progress and continuing its development as part of Axel Johnson International.
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NEWS 10 HYDRAULICS & PNEUMATICS June 2026 www.hpmag.co.uk manufacturers report using less than half of the operational data they collect effectively, pointing to a persistent gap between data generation and decisionmaking. Closing this gap is likely to be one of the most important factors in determining future competitiveness. More broadly, UK manufacturing is showing clear signs of maturity. Smart manufacturing technologies are now widely deployed, and adoption is accelerating as organisations focus on scaling what works rather than piloting new tools. Artificial intelligence is increasingly seen as the technology most likely to deliver meaningful operational improvements, reinforcing its central role in the next phase of industrial transformation. Taken together, the findings suggest that UK manufacturing is entering a new phase of digital transformation. The foundations have been laid, investment is established and adoption is widespread. The next challenge is execution — turning digital capability into consistent, scalable performance in an increasingly complex industrial landscape. UK at a glance 87% of UK manufacturers say digital transformation is essential 27% of operating budgets allocated to industrial technology 49% have already invested in AI, with 38% planning further investment 53% have invested in generative AI, with 33% planning adoption Cybersecurity is the leading AI use case at 48% 62% have invested in cybersecurity technologies Cybersecurity is the leading AI use case for UK manufacturers, cited by 48% of organisations 27% have deployed digital twins, with 47% planning investment (88% total) 45% of operational data is used effectively 40% cite rising labour costs as the top workforce challenge 36% cite change management as a key barrier 38% of employees are engaged in reskilling programmes 48% identify AI as the technology with the greatest operational impact Danfoss enters exclusivity agreement to acquire Alfagomma Danfoss has recently announced it has entered into an exclusivity agreement to conclude the acquisition of Alfagomma. The intention to acquire Alfagomma aligns with Danfoss’ LEAP 2030 strategy, part of which is to accelerate profitable growth within the Fluid Conveyance division, a core business within the Danfoss Power Solutions segment. Alfagomma, headquartered in Italy, is a leading global manufacturer of hoses, fittings, couplings, and connectors with approximately EUR 600 million in annual sales, 4,500 employees, and operations across 28 production and assembly sites globally. Combining the businesses of both Alfagomma and the Fluid Conveyance division would create a global leader in hydraulic and industrial hose manufacturing and distribution. Since 2021, Danfoss has significantly strengthened its Fluid Conveyance business through the acquisition of Eaton’s Hydraulics business and, most recently, Hydro Holding in Italy, while continuing to invest in equipment, technology, and infrastructure. Today, Fluid Conveyance is a core and fastgrowing business within Danfoss Power Solutions. Both companies will operate independently throughout the process, maintaining continuity and business as usual for customers, suppliers, and employees. Danfoss intends to complete the transaction and remains strongly committed to investing in the business and maintaining the footprint in Italy. Since 1961, Danfoss has sustained a strong presence in Italy with a current workforce of more than 1,100 employees across 14 sites. Danfoss considers Italy a core country for future development, with a clear long-term commitment to strengthen the operations, support the industrial base, and ensure stability, growth, and continued investment in the people, capabilities, and operations of Alfagomma. BT and Ericsson have joined the Manufacturing Technology Centre (MTC) as members, helping to accelerate the adoption of 5G technologies across the UK manufacturing sector. Through the membership, BT and Ericsson will deploy and showcase a portfolio of 5G-enabled manufacturing demonstrations at MTC’s facility, underpinned by indoor and outdoor 5G standalone connectivity delivered through Ericsson’s Private 5G solution. BT’s advanced 5G network capabilities, Ericsson’s global leadership in 5G solutions, and MTC’s expertise in industrial innovation will enable UK manufacturers to explore, test and scale 5G-enabled production in a realistic environment. This live end-to-end 5G environment will allow manufacturers to see applications in action, understand the business case, and work with experts from BT, Ericsson and MTC to develop proof of concepts, and shape pilots and deployments in their own factories. Demonstrations will showcase automated smart factory applications, including a 5Gconnected battery recycling line, predictive maintenance using connected sensors and AI analytics, and extended reality for immersive training and operational support. Over the next three years, BT, Ericsson and MTC will expand and refresh the demonstrations in line with the industry’s shift to increasingly autonomous, software-driven, intelligent factories, ensuring the work remains tightly aligned to the UK’s industrial priorities. Joe Darlington, Director of Engineering at MTC commented: “Advanced and reliable connectivity is fundamental to allowing digital systems to work together seamlessly on the factory floor.?By welcoming BT and Ericsson into our membership, we can give industry an ideal environment to explore, trial and adopt 5G solutions, helping UK manufacturers to leverage digital technologies and harness them to enhance productivity and business growth.” BT and Ericsson join MTC to accelerate 5G adoption in UK manufacturing
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NEWS 12 HYDRAULICS & PNEUMATICS June 2026 www.hpmag.co.uk Siemens has recently announced the appointment of Brian Holliday as chief executive officer (CEO) for the UK and Ireland. In the role, Holliday will lead Siemens’ strategy and engagement across the UK and Ireland, where the company employs 12,000 people and generated £4.6 billion in revenue in financial year 2025. Holliday has worked for Siemens for more than 32 years in a range of technology and leadership roles. He has worked with companies across the industrial spectrum to create value through technology and has been a noteworthy contributor to the UK innovation, industrial policy and skills landscapes. He will continue as managing director of Siemens Digital Industries and build on more than 10 years as a member of the UK and Ireland senior leadership team. “Brian brings a deep understanding of our strategic priorities and our customers, as well as strong insight into the challenges facing industry as it digitalises. His external experience with the Catapults and Made Smarter will also be a real asset,” said Matthias Rebellius, Managing Board Member of Siemens AG, responsible for UK and Ireland. “Brian will build on the strong foundations already in place, continuing to drive focus on the areas where we can make the greatest difference and create more value for customers. This will be even more important as we take forward our ONE Tech Company programme and ensure we serve our customers in a seamless, straightforward way.” Rebellius added. Holliday commented: “I’m honoured to take up this position at a time of significant change, where technology and talent can make a real difference. I’ve always been proud of our people and struck by the commitment and sense of purpose evident across our UK and Ireland organisation – thus I’m genuinely excited to lead this strong team. With global leadership in industrial technology and AI, as well as the partnerships we’ve developed, Siemens is well set to help our customers with their competitiveness, resilience and sustainability.” Holliday is a Fellow of the Royal Academy of Engineering and visiting Professor at the University of Sheffield. He holds degrees from Cardiff University and the University of Manchester as well as an honorary doctorate from Middlesex University. He began his career as an apprentice with Texas Instruments and remains a strong advocate for applied learning and vocational training. He has contributed to the UK’s innovation, skills and industrial policy agendas through non-executive and committee roles, including the High Value Manufacturing Catapult, Make UK and as Co-Chair of the Made Smarter Commission which works with SMEs to improve manufacturing productivity. Most recently, he was appointed to the board of Skills England where he formally advocates for SMEs and social mobility. Brian Holliday appointed Chief Executive Officer of Siemens UK and Ireland The winners of The Big Bang UK Young Scientists & Engineers Competition have been named. Held at The Big Bang Fair, the awards ceremony followed a daylong showcase of talented young innovators. The Big Bang Competition, run by EngineeringUK, is a prestigious national competition for young engineers, scientists and technologists aged 11 to 18. There are a range of awards and prizes up for grabs, recognising and rewarding talented STEM innovators. The top 3 winners each receiving £1,000 prize money. Kanav Jain, a student from Broxburn, Scotland has been crowned UK Young Engineer of the Year, supported by Thales, for his project ‘AeroAid: autonomous VTOL quadplane’. Kanav is currently in S4 and entered via a community group – First Step Robotics. Kanav was inspired to help people in rural and remote regions where the delivery of essential emergency supplies is challenging due to lack of reliable road access. Using his passion for drones, he Winner of UK Young Engineer of the Year revealed has designed and developed a small, low-cost autonomous aircraft that can carry and deliver medicines and other essential supplies quickly and efficiently. Kanav hopes his low-cost, accessible invention will help provide critical Awards ceremony: Mike Sewart (Chief Technology Officer at Thales), Kanav Jain (winner), Dr Hilary Leevers (Chief Executive of Engineering UK)
AWARDS OPEN TO EVERYONE We’re celebrating the very best in the electro-mechanical service and repair industry — and every company is invited to enter. Big or small. First-time entrant or seasoned contender. If you, your company, a project, or a product/service offering is making an impact, we want to hear your story. The 2026 AEMT Awards Join the industry celebration: Thursday 19th November 2026 Doubletree by Hilton, Coventry 30th Sep Judges Convene 20th Apr Nominations Open 11th Sep Nominations Close 19th Nov Winners Announced 9th Oct Finalists Announced Entry is free of charge and multiple entries are not only allowed, but encouraged! For more information and to submit your entries, please visit: AEMTAWARDS.COM Enter one (or more) of the 10 categories: • Product of the Year • Project of the Year • Supplier of the Year • Rising Star • Diversity in Engineering • Service Centre of the Year – Large • Service Centre of the Year – Small • Electro-Mechanical Champion of the Year • Contribution to Skills and Training • Sustainable Organisation of the Year Sponsors: More sponsorship opportunities available!
NEWS 14 HYDRAULICS & PNEUMATICS June 2026 www.hpmag.co.uk The number of NEETs and the UK’s benefit bill could fall within 3 years, if government and industry manage to close the skills gaps and shortages that plague our economy, leading skills charity Enginuity has said. A new report, from Enginuity, the former Sector Skills Council for engineering and manufacturing, SEMTA, shows that the skills gap in the engineering and manufacturing sector is costing the UK more than £5Billion a year - and if not addressed with urgency, will cast further adrift the ‘lost generation’ identified by Alan Milburn. The report, entitled, Mind the Gap, says that the sector faces a ‘perfect storm’ of interrelated factors which will only make matters worse over time. The £5bn lost annually to skills shortages represents a major missed opportunity. Based on typical starting salaries in the sector, it would be equivalent to supporting over 300,000 apprenticeships each year— a scale of intervention that could materially reduce the number of those not in education, employment or training (NEET) by 30% and help to reduce pressure on the benefits bill. Ann Watson, CEO of the charity Enginuity, the former Sector Skills Council which commissioned the report, said: “ “The findings highlight a significant productivity challenge for our sector but also a clear opportunity. At a time when NEET numbers & benefits pressure could tumble if skills gap is filled says Enginuity Government backs UK battery manufacturing The UK Government has announced a £380 million grant to support Agratas’ plans to build a battery gigafactory in Somerset. The facility, which will produce battery cells for Jaguar Land Rover, is expected to support around 4200 direct jobs, create 300 apprenticeships and generate opportunities across the manufacturing supply chain. The announcement forms part of the Government’s Modern Industrial Strategy and is intended to strengthen domestic battery production while supporting investment in advanced manufacturing. Alongside the Agratas funding, additional support has been announced for battery research and development projects and automotive businesses developing electric vehicle technologies. According to the Government, the measures are designed to boost investment, strengthen supply chains and support long-term growth across UK manufacturing. the UK is striving to boost growth, we cannot afford to see talent, investment and potential go to waste. We have a generation of young people struggling to access good work, employers crying out for skilled talent and growing economic inactivity placing increasing pressure on public finances. The solution is there in front of us. “Government needs to take note of these findings and ensure they are reflected in efforts to remove barriers to growth and talent entering the sector.” “Through The Policy Centre for Supply Chain and SMEs: Powered by Enginuity, we will be feeding these findings and recommendations directly to government and work with them to bring about change.” The survey evidence, from SQW, demonstrates that skills challenges are particularly widespread among engineering and manufacturing SMEs. Around half of surveyed SMEs (small and medium sized companies), reported skills related issues in the past year, with 36% experiencing skills gaps and 35% reporting skills shortages. Where skills gaps exist, firms estimate that around one in five employees are affected, while SMEs facing shortages typically report two to three hard to fill vacancies. SMEs report shortages in core technical and manual skills alongside growing gaps in digital, data and managerial capabilities. These challenges are not confined to humanitarian support and save millions of lives. Upon winning Kanav commented “It’s so surreal! The moment they say your name you completely zone out…because of how much effort you put into it, and to see all of that come to life is really great!” James Mackay, Head of STEM, UK at Thales commented: “Congratulations to The Big Bang UK Young Engineer of the Year. We were delighted to see the creativity and impressive STEM skills from all the finalists. Kanav’s project really impressed the judges, along with his tenacity, dedication and drive. “Supporting these future engineers is truly exciting for us at Thales. The Competition is a great reminder that the next big breakthrough could come from anyone. We need many more young people to pursue STEM careers. It’s been great to see so many students thinking about how they can innovate and create real-world solutions with engineering.” entry-level roles and are most commonly associated with lost productivity, with knock-on effects for turnover and future growth. Based on survey evidence and economic modelling, it is estimated that skills related challenges cost the engineering and manufacturing sector approximately £5.2bn per year, equivalent to around 10% of their annual output. At an individual business level, affected companies may be losing as much as 10% of their annual Gross Value Added (GVA), - equivalent to approximately £110,000 per company, per year. Ann Watson, CEO of the charity Enginuity
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HYDRAULICS Hydraulic power units (HPUs) remain fundamental to industrial and mobile equipment, delivering controlled force and motion across a wide range of applications. While hydraulic principles are well established, modern systems increasingly demand higher levels of efficiency, integration, reliability and control. Hydrastore and Related Fluid Power, working in conjunction with DCA as a dedicated technical and applications partner, explain that HPU development is approached from a system perspective. Rather than focusing solely on component supply, the emphasis is placed on understanding the full application context—operating conditions, duty cycles, environmental constraints and control requirements—and translating these into a complete, engineered solution. Julian Lee, Director at DCA Ltd, explains that his company plays a key role at the front end of this process, working directly with customers to define system requirements and control philosophy. This structured approach ensures that hydraulic, mechanical and electrical elements are aligned from the outset, reducing integration risk and improving overall system performance. Energy efficiency and operational visibility are increasingly central to HPU design. Systems are developed to make effective use of power through the correct pump control application, optimised hydraulic layouts and, where appropriate, variable speed drive technology. These approaches reduce energy consumption while maintaining required performance levels. Hydrastore and Related Fluid Power say they combine practical application experience with component-level expertise to ensure appropriate selection of pumps, valves, filtration and cooling systems. Thermal management and fluid conditioning are considered early in the design process to maintain system stability and extend component life. Integration with modern control environments is also a key requirement. HPU systems are routinely supplied with sensors and instrumentation to monitor pressure, flow and temperature, alongside control interfaces that support PLC integration or standalone operation. All companies support the development of control software, considering safety, automation and remote communication capability where required. Space constraints, mobility and environmental conditions are increasingly influential in system design. Related Fluid Power focuses on compact and modular HPU configurations suited to space-limited, while Hydrastore delivers larger industrial units designed for robustness, maintainability and compliance with relevant standards. Across both areas, systems are engineered for ease of installation and integration, whether as part of new equipment or retrofit into existing plant. This includes consideration of mounting arrangements, connection points and accessibility for service and maintenance. Full equipment lifecycle is also a key aspect considered by Hydrastore, Related Fluid Power and DCA, says Lee. This includes initial specification and design, system build, testing and commissioning, as well as ongoing service, modification and technical support. By combining application knowledge with engineering and integration expertise, complete HPU systems can be delivered that are aligned to the specific operational demands of each project. This approach reduces complexity for the end user while supporting reliable, efficient and maintainable hydraulic systems. Hydraulic power units require more than effective component selection; they depend on coordinated system design, integration and control. Lee concludes that, through the combined capabilities of Hydrastore, Related Fluid Power and DCA, HPUs are developed as complete, application-specific systems that address performance, efficiency and integration requirements in demanding industrial and mobile environments. 16 HYDRAULICS & PNEUMATICS June 2026 www.hpmag.co.uk A system approach to hydraulic power unit design Subsea Wellhead Abandonment System A complete HPU and control system was developed for the operation of subsea wellhead abandonment equipment in a marine environment. The unit was engineered for offshore deployment, incorporating stainless steel construction and marine-grade coating systems to ensure durability. The HPU was mounted within a transportable frame suitable for installation inside a standard shipping container, supporting deployment flexibility. Dual motor-pump units (15 kW load-sensing piston pumps) were incorporated to provide operational redundancy. The system supported 22 hydraulic work functions, with additional spare capacity. Instrumentation included distributed pressure and flow sensors, enabling system-wide monitoring. An integrated control console with touchscreen interface provided operator control and diagnostic feedback. The control system, developed inhouse via Hydrastore control team, included data logging of all work functions and sensor outputs, software-based safety interlocks and remote communication capability, allowing monitoring and operation from a remote location if required. Manual override of valve functions was also incorporated at panel level. The unit was supplied fully documented, including operational guidance and spares support, and underwent full factory acceptance testing prior to delivery. For further information please visit: https://www.dca-ltd.com
Watchlog Connect Hydraulic test & monitoring software TEST. MONITOR. DATALOG. REPORT. Cross-platform software for hydraulic testing, data logging and instant PDF reporting. REAL-TIME MONITORING WIRED CONNECTIVITY WIRELESS CONNECTIVITY INSTANT REPORTING FAST DEPLOYMENT. SAFER WORKING. INSTANT REPORTING. hydrotechnik.co.uk/connect +44 (0) 115 900 3550 sales@hydrotechnik.co.uk USB (up to 5mS recording) Bluetooth (up to 20m) Bluetooth Plus (up to 50m) Wireless (up to 500m) Wireless Plus (up to 800m) CANBus up to 24 channels Universal sensor inputs over Bluetooth, Wireless & USB • Pressure • Flow • Temperature • RPM • Level • Displacement • Force • Calculations • Mathematical Formulae Reduce testing time, improve reporting accuracy and monitor machinery safety from a distance with Watchlog Connect. Trusted by hydraulic professionals to capture, analyse and report data with confidence MULTI�PLATFORM SOFTWARE PC, MAC, Android, iOS Desktop, Tablet, Smartphone PDF INSTANT CSV FILES CSV CANBUS MONITORING & LOGGING PDF Reporting 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
HYDRAULICS 18 HYDRAULICS & PNEUMATICS June 2026 www.hpmag.co.uk The average manufacturing site reports 800 hours of unplanned downtime per year, with system failures costing upwards of $50B annually1 – including direct repairs, lost output, and delayed deliveries. Beyond safety and environmental incidents, few operational disruptions carry a greater financial impact than unexpected downtime in an industrial or manufacturing facility. In fact, 82% of companies report having experienced unplanned downtime within the last three years, with the majority encountering multiple incidents during that period. These failures rarely result from sudden, catastrophic breakages. More often, they originate from incremental issues: connectors loosening under vibration, hoses losing kink resistance, components compromised by thermal cycling, or fittings degrading from repeated exposure to aggressive cleaning agents and hydraulic fluids. As industrial processes intensify, understanding how these factors interact is essential to maintaining reliable operations. The challenge of compound stress In modern industrial environments, connection systems are exposed to multiple simultaneous stresses. Hydraulic pressure creates continuous mechanical loading, while vibration from automated equipment adds cyclic stresses to joints. Thermal cycling—machines starting cold and running hot during each shift— causes repeated expansions and contractions that can subtly change connector geometry and reduce clamping force over time. Over thousands of operating cycles, a connection installed correctly can lose preload as surfaces wear and assembled fittings relax. Threaded or clamped joints may loosen incrementally, while sealing interfaces degrade, compromising leaktight performance. Meanwhile, exposure to hydraulic oils, cooling fluids, and cleaning agents requires connectors to be manufactured from materials and coatings resistant to corrosion and dimensional instability. At Building leak-free reliability in extreme industrial environments pharmaceutical applications, and areas exposed to aggressive cleaning agents where metallic fittings are more prone to corrosion And for applications where extreme mechanical stress dominates—whether from severe pressure fluctuations, continuous heavy loading, or safety?critical duty—metal-to-metal fittings deliver the secure mechanical engagement and long-term stability essential to these demanding conditions. Metal-to-metal connectors for durability Metal-to-metal fittings, including EO-PSR, Triple-Lok, and A-Lok designs, achieve long-term stability through controlled deformation of hardened cutting rings or conical sealing surfaces. These create multiple contact points and a secure mechanical lock with the tube. For safetycritical applications, tear-out-resistant designs capture the tube securely, ensuring connections remain intact under sudden surges, vibration, or thermal shock while meeting industrial safety standards. These fittings operate reliably over extended operating cycles with minimal retightening. Their rigid engagement avoids cold flow issues and maintains connection integrity during hydraulic spikes, making them ideal for highpressure machinery subject to dynamic Unexpected downtime rarely stems from a single failure. In demanding industrial environments, leak-free performance depends on selecting the right connection technologies, ensuring system compatibility, and designing for the combined effects of pressure, vibration, thermal cycling, and chemical exposure. the same time, the increasing complexity and integration of industrial facilities multiplies the number of potential leak points. Connectors must not only maintain integrity but also fit into compact spaces and support proper assembly and disassembly during scheduled maintenance. Preventing leaks or failures is not about a single “fix,” but about engineering every connection to cope with these combined stresses. Putting connection choices in context System reliability starts with selecting appropriate connection technologies based on specific operational demands. In applications with significant vibration and cyclic loading, soft-sealed fittings such as EO2, EO2?FORM, and O?Lok combine precision-machined metal with elastomeric sealing elements, simplifying assembly, supporting multiple reinstallations, and maintaining reliable performance across a wide range of pressures and temperatures. Where chemical exposure presents the primary challenge in low- to mediumpressure applications, advanced polymer fittings made from engineered polyamide and other specialized materials provide high chemical resistance, low weight, and rapid assembly. These are particularly effective in food processing,
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20 HYDRAULICS & PNEUMATICS June 2026 www.hpmag.co.uk HYDRAULICS mechanical loads. And because both tube and fitting have comparable thermal expansion properties, connections resist preload loss during thermal cycling – something elastomer seals are more prone to. But beyond the choice of fitting, hose assemblies play a critical role in preserving long-term reliability. Tailored bend radii, abrasion-resistant covers, and multi-layer reinforcement prevent kinking and absorb movement, reducing mechanical stress at the joint. By relieving strain during vibration and thermal cycling, well?designed hoses help fittings maintain their sealing force over extended service life. Designing for compatibility and long-term performance International standards provide the foundation for connector reliability, allowing safe interchangeability between manufacturers: DIN 2353 defines geometry and performance for bite-type fittings. ISO 8434-1 is largely harmonized with DIN 2353, setting global specifications for compression fittings, ensuring consistent burst pressure ratings, material properties, and vibration resistance. SAE standards are prevalent in the US, while DIN standards predominate in Europe. In specialised sectors, additional certifications—such as FDA and USDA hygiene approvals or environmental directives like RoHS and REACH—guide material choices and connector finishes. Considering these requirements early in system planning supports long-term reliability and traceability without costly redesigns or downtime. Meeting standards alone, however, does not guarantee leak-free performance. Assemblies that mix hoses, connectors, and finishes from different suppliers may pass individual certifications but fail as a system. Minor tolerance mismatches or incompatible surface treatments can create sealing gaps that bypass fluid under pressure. Designing with fully compatible components, tested together and compliant with shared standards, reduces these risks and simplifies maintenance and auditing. Furthermore, many leaks result from incorrect torque, mismatched replacement parts, or contamination at sealing surfaces. Shifting from reactive repairs to predictive maintenance helps mitigate these risks. Regular inspections, scheduled component replacements, and integrated pressure and temperature monitoring—including advanced sensors and diagnostic tools for early leak detection—allow operators to detect early signs of connector wear or degradation. Combined with consistent standards and system-level compatibility, proactive maintenance forms a comprehensive approach to achieving longterm connector reliability. Achieving leak-free system performance Leak-free dependability depends on precise engineering and disciplined maintenance, not on any single component. Selecting seals and fittings that match the pressure, temperature, and chemical conditions of each application; designing assemblies with compatible, standards-compliant components; and adopting proactive monitoring practices together determine whether a system runs safely and efficiently. Solution providers such as Parker, with a broad portfolio of connection technologies, are well positioned to support this approach. By offering fully compatible components tested as complete systems and sharing fieldproven installation and maintenance practices, we help manufacturers maintain safe, efficient, and leak-free production – even in the most demanding industrial environments. 1 Forbes: https://www.forbes.com/councils/forbestec hcouncil/2022/02/22/unplanneddowntime-costs-more-than-you-think/ Article contributors: Alexander Hertje, Market Development Manager Innovation, Hose Division Europe, Parker, Philipp Wagener, Metals Innovation Center Manager, High Pressure Connectors Europe, Parker & Richard Boulom, Quality Support Engineer, Low Pressure Connectors Europe, Parker For further information please visit: www.parker.com
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