Servicing Hydraulic Systems for Harbour Authority

At Rotec Hydraulics, we believe that a well-maintained hydraulic system is the backbone of efficient and reliable operations. We recently carried out essential hydraulic power unit (HPU) servicing for a returning customer – a major harbour authority in Devon.

Our experienced engineers carried out a thorough service of the client’s HPU, including:

  • HPU Draining & Oil Replacement: We began by draining the old hydraulic oil from the HPU, preparing the system for a fresh start.
  • Critical Hose Replacements: The project required the replacement of two steering system “severe rated” hydraulic hose assemblies. Our engineers manufactured new hoses, making them 150mm longer to allow for better routing around a tie-rod. This small modification significantly reduces wear and tear and extends the life of the hoses. We also identified and replaced two additional hose assemblies with damaged outer sleeving, preventing potential future failures.
  • Component Inspection & Servicing: We removed and inspected the slow stow adjuster and its associated solenoid. This step involved servicing, cleaning, and replacing seals as needed, ensuring these components operate flawlessly.
  • System Flushing & Filtration: To guarantee a clean system, we installed a temporary hydraulic filter in the Man Overboard (MOB) system. We then refilled the tank with BIO ISO-32 oil and ran the system through, directing the flow of oil through the pressure filter to effectively flush out any contaminants.
  • Final Commissioning: After the flushing process, we reinstated the system, carefully bled the lines, and performed a comprehensive commissioning to ensure everything was functioning correctly. We also performed fault-finding on the MOB system, addressing any issues proactively.
  • Site Clean-up: We believe a job isn’t complete until the site is left clean and tidy, a final touch that underscores our professionalism and respect for our client’s workspace.

 If you are looking to secure the longevity and reliability of your hydraulic systems, a proactive maintenance plan is a wise investment. Contact Rotec Hydraulics today to learn how our team can help you safeguard your operations via sales@rotec.net or phone 01823 348900.

100% Achilles audit _Rotec Hydraulics Ltd

Streamline Your Manufacturing with Rotec’s OEM Kitting Service

In today’s competitive manufacturing landscape, efficiency and cost-effectiveness are paramount. Original Equipment Manufacturers (OEMs) are constantly seeking ways to optimise their operations, reduce lead times, and improve productivity. One solution is Rotec’s bespoke kitting service -streamlining your assembly lines and reducing lead times, it helps improve your time-to-market and gain a competitive advantage.

What is an OEM Kitting Service?

OEM kitting involves assembling all the necessary components for a specific product or sub-assembly into a single, convenient kit. This can include everything from hose assemblies, adaptors, seals, and o-rings, to pumps, valves, oils, and filters – essentially, any component your product requires. Rotec Hydraulics works closely with OEMs to tailor these kits to their exact specifications, ensuring every part is present and accounted for.

How Rotec’s Kitting Service Benefits Your Business:

Our OEM kitting service is designed to be a complete solution, offering a range of value-added services, including:

 

  • Customized Kitting: We work with you to understand your specific needs and create kits that perfectly match your requirements. No more searching for individual parts – everything you need arrives in one package.
  • Comprehensive Component Sourcing: We handle the procurement of all necessary components, saving you time and effort. Our extensive network of suppliers ensures access to high-quality parts at competitive prices.
  • Value-Added Services: We can include testing, labeling, bagging, and other services to further streamline your production process. Just let us know your requirements, and we’ll take care of the rest.
  • UK and European Coverage: Rotec Hydraulics serves clients across the UK and mainland Europe, ensuring consistent supply regardless of your location.
  • Reduced Costs and Improved Efficiency: Kitting can significantly reduce your purchasing activity, speed up goods receipt, and improve productivity. By consolidating your supply chain, you can also reduce the number of suppliers you need to manage, leading to fewer invoices and simplified administration.

“Rotec’s kitting service has streamlined our assembly lines, reducing assembly time and boosting productivity.”

Purchasing Manager

Marine industry

Partner with Rotec Hydraulics:

If you’re looking for a way to optimise your manufacturing processes and improve your bottom line, consider partnering with Rotec Hydraulics for your OEM kitting needs.

Contact us today to discuss your requirements and discover how we can help you achieve your goals. Let us help you build a more efficient and competitive business.

Get in touch

Hose Test Rigs for the Motorsport Industry

100% Achilles audit _Rotec Hydraulics Ltd

Rotec Hydraulics Ltd designed, built and commissioned two identical hose test rigs for a UK manufacturer who supplies world-leading racing teams with fluid transfer assemblies, hose and fittings.

UKCA/CE certificated and labelled, the test rigs are designed to provide regular and rigorous testing for a variety of flexible hose assemblies. The rigs were based on an existing design, but updated and improved due to the obsolescence of some of the components.

Measuring over 3 metres in length, the main capabilities of the test rigs include:

  • Testing hoses up to four hoses at a time
  • Testing hoses up to 250bar pressure using water as the medium.
  • An air supply is used to control the hydraulic (water) valves and is used to pressurize the water using a 60:1 air/water intensifier.
  • A low-pressure pump provides a means of flushing and pre-filling the hoses under test.
  • Clean, filtered and dried compressed air supply of guaranteed continuous pressure of 6 bar minimum.
  • Power supply of 240VAC 1 PH 50Hz 16A maximum for UK use.
  • Nominal test sequence, based on existing rigs, (i.e., prefill/flush, test, vent, purge).
100% Achilles audit _Rotec Hydraulics Ltd
100% Achilles audit _Rotec Hydraulics Ltd

Each rig consists of a grade 316 stainless-steel upper half, and a powder coated steel lower half and electrical enclosure.

The lower half consists of the water reservoir, an air tank, an intensifier, a low-pressure pump, pneumatically operated hydraulic valves and a pneumatic control system. All the valves, which water flow through, high-pressure pipework & reservoir are made of grade 316 stainless steel to prevent corrosion. There are two lockable hinged doors on the front and three lockable panels on the rear to allow access for maintenance as well as internal led strip lights for enhanced lighting.

Inside the upper enclosure are eight ½” BSP ports (four either end) to which up to four hose assemblies can be installed for testing at up to 250 bar pressure. Bi-fold doors with transparent windows are fitted to enable access to the hoses, the doors are fitted with interlocks to ensure they cannot be opened whilst the hoses are under test. Internal led strip lights are built into the top of the enclosure to provide enhanced lighting. There is also a water filling point and drain which connect to a reservoir in the lower half of the rig.

Attached to the right-hand side of the rig is the Rotec designed lockable electrical enclosure which houses the customers electrical components. On the front face of the enclosure are controls for adjusting the test pressure, starting/stopping the testing cycle as well as an information screen displaying the results of the testing.

2 manually operated panel mountable air regulators were incorporated into the design. One is set and locked at 4.2bar inside the lower area (i.e., beyond the reach of the operator), the other panel mounted in the user control panel. This second unit is fed from the outlet of the former, ensuring the user cannot inadvertently set the test pressure to rise above the setting of the former and thus inadvertently (or intentionally) over-pressurise the system.

Rotec’s customer said:

“I am very pleased with the finished machine. As I expected, everything has been finished to a high standard.”

If you are interested in a similar project or any hydraulic power systems, do not hesitate to contact the team today on 01823 348900 or email sales@rotec.net.

Kitting Services and Hose Assemblies tailored to your needs

Looking to reduce inefficiency and increase your team’s capacity?

Eliminate non-value added activities and increase your productivity with Rotec’s Bespoke Kitting Service.

 

All components and sub-assemblies are labeled and packaged neatly together with a list detailing parts and quantities for your convenience. 

Whether you need basic to the most complex kits with multiple assemblies, Rotec Hydraulics delivers kit solutions to help you meet performance goals.

Benefits

  • Simplifies Inventory Management: Reduces volume of individual components to stock manage.
  • Increases Productivity: Your team no longer need to pick parts from different areas. Instead they have a kit ready to go so they can get on with the job in hand.
  • Reduces Manufacturing Time: Kits are tailored to your needs and can include pre-assembled items.

Getting Started

  • Establish a Bill of Materials: Identify items and quantities.
  • Identify Packaging Requirements: Define custom tagging/labelling.
  • Specify sub-assemblies: Decide if any pre-assembled items are required.
  • Request Custom Quote: Email sales@rotec.net or phone 01823 348900 to speak to a member of our team. 
It’s that simple!  Get started by clicking the button below and our Sales Team will be in touch to discuss your requirements.
ENQUIRE TODAY

Rotec’s repair and overhaul service reduces running costs by 10% at leading manufacturer

Machine prior to overhaul
Overhaul completed, outer door refitted and ready for re-paint

Following a major failure during operation, a large flooring, MDF and OSB manufacturer asked Rotec to carry out extensive repairs on an industrial wood chipper.

Owing to the failure occurring whilst the machine was in use, the Maier Wood Chipper machine had suffered severe damage internally and so required a thorough repair and overhaul service.

After Rotec engineers stripped the machine and checked all components, it became apparent that the shaft bearing sleeves had failed, worn the housing and as the blades had come away during the failure, many internal parts were damaged and required either replacement or upgrading.

As the customer had issues with levelling up the impellor blades, Rotec checked the laser alignment and then ‘clocked’ the rear datum locating ring support pads on the machine. The support pads were found to have a 0.7mm difference in their positioning which, may have been a contributing factor to the issues leading to the initial failure. On discussion with the client, it was decided to build up the lower blocks and design and build a tool for machining the pads in-situ.

Once the chipper had been repaired, overhauled, re-painted and fitted back onsite at the customer’s facility, the client was so pleased with Rotec’s workmanship and project management that Rotec have now taken delivery of another unit from the same workshop for a complete overhaul.

The Engineering Managing of the flooring, MDF and OSB manufacturer has since reported that the overhaul and rebalancing of the machine is so good that the company is achieving a higher output rate and saving 10% on the machine’s previous running cost.

Laurence White, Business Development Manager for Rotec Hydraulics Ltd, commented;

“It has been a pleasure to be part of this thorough overhaul and repair service. Our team take pride in knowing that we have delivered a high level of workmanship and have not only helped to increase efficiency, but also have helped to reduce running costs for our client. We look forward to a long lasting relationship with our customer.”

For more information regarding Rotec’s capabilities, including the overhaul and repair service, contact sales@rotec.net or phone 01823 348900.

Chipper unit prior to Rotec overhaul

Damage caused by external conveyor belt

Damage to internal shaft

Internal damage caused during failure of blades

Modifications to front lower section to allow for outer adjustment on longer support sections, manufactured and fitted support bars

Die penetration checks on welding

Special support structure manufactured for accurate machining of the rear ring support pads

Inner bladed impellor fitted and clocked to ensure true

Outer door refitted on chipper

Chipper Completed unit back onsite at customer’s facility

Bespoke hydraulic ring main and multiple air blast coolers installed at leading Aerospace Engineering company

Rotec Hydraulics Ltd was chosen by leading aerospace and engineering business to complete a 3-phase upgrade project to its existing Structural Test Lab (STL) hydraulic ring main. The team at Rotec successfully completed the project on time and to a high level of quality.

A global leader in Aerospace, Defence and Security, our client is a key supplier of defence and security equipment to the UK MoD, employing over 7,500 highly skilled personnel across 7 main sites throughout the UK.

A crucial asset at their Somerset facility is its Structural Test Laboratory (STL), which is responsible for mechanically testing critical aircraft components to destruction. As part of an ongoing development programme, the client wanted to create a dedicated and permanent hydraulic supply to its expanding fleet of testing equipment.

Rotec Hydraulics Ltd added several significant upgrades to the current system in three stages; install 4 air blast coolers, design and install a custom sub ring main within the new Fatigue Lab and finally to design and install a major upgrade to the existing distribution ring main.

As part of the second and final phases of the project, Rotec designed and built a number of bespoke pipework brackets, stands and manifolds all of which were FEA tested by our in-house design engineers to ensure they exceed the minimum design requirements set by the customer.

More than 21.5 metres of pressure and return pipework was manufactured on site using Parker’s unique High Pressure Flange system making for a very quick and efficient installation. The 80 x 10mm 6k steel pipework is capable of operating at 420 bar maximum working pressure and was connected using Rotec’s in-house designed “X-Blocks” which distributed the flow to numerous outputs.

Rotec’s capabilities are that of significant breadth meaning, unlike many competitors, Rotec is able to design, build, install, commission and maintain systems in-house to a consistently high standard. To find out more, visit our services page.