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

Rotec Hydraulics launches first-of-its-kind Electric Winch System

Our team at Rotec Hydraulics Ltd, experts in system solution design, have developed a pioneering electric winch system that offers a zero-emission alternative to hydraulic winches. This innovation supports customers in achieving net zero goals with enhanced performance and precision.

“This project is an example of how Rotec Hydraulics is spearheading electrification within the fluid power industry to enable decarbonisation of the hardest-to-abate industry sectors.

“The addition of Parker components, including IQAN technology, has made the challenge of producing the same, if not enhanced, performance compared to the equivalent hydraulic winch system solution possible.”

– Paul Prouse, Managing Director of Rotec Hydraulics Ltd.

Our in-house design team have innovatively designed and developed the first-of-its-kind electric winch system in response to a request from a client. The customer, a national company working within the utilities sector, has ambitious net zero goals and Rotec, as its sole winch design, supply and service provider was keen to support.

Expertise in system solution design

The ambitious R&D project was specifically dedicated to produce an electric winch with the equivalent performance and functionality of the hydraulic winch that the client currently uses on their large fleet of Isuzu D-Max vehicles.

Stepping up the design challenge

Despite other winch providers saying an electric winch system capable of proportional speed control lifting 1.5 tons and dragging 3.6 tonnes and not overheating was impossible, we are pleased to reveal our new offer to the market.

This particular example features two operational modes (lifting and pulling). The proportional speed control allows for safe, controlled ascent and descent of the winch system when lifting.

Operators have reported that the infinite winch speed control using joysticks in cab and/or remote pendant have allowed for more precise and accurate placing of the load than the previous hydraulic winch delivered.

The integrated thermal management of both motor and motor inverter along with natural air cooling of the motor inverter, means that Rotec’s electric winch system has an unlimited run time.

The electric winch system is fully customisable to any future clients looking to change to fully electric winches.

Sustainability

Our electrical winch system reduces CO2 emissions as a result of being powered by a lithium battery, rather than the vehicle’s diesel engine.  The vehicle engine does not need to be turned on in order to operate the winch, unlike its hydraulic counterpart. 

The electric winch’s carbon emissions are minimised with the only emissions being those generated when the vehicle is in motion and it is charging the winch system’s lithium battery.

Not just a supplier of parts

Winner of Manufacturer of the Year 2023 at the Somerset Business Awards, we can provide tailored winch system designs to your vehicle and operational requirements and offer design, manufacture, fitting and on-site servicing and repair service backed with consistent excellent customer service. 

Customers can customise rated line pull, line speed or rope type and capacity to optimise their operations. High quality, robust components mean all Rotec winch systems are suitable for operating in challenging environments.

Our innovative electric winch system has enabled its customer to not only cut emissions but work smarter, more accurately and increase productivity with proportional control capability and/or remote monitoring options.

 

Find out more about Rotec’s winch offer at Winch systems – Rotec Hydraulics Ltd.

Two HPUs and Ten Jacking Cylinders Manufactured for New Client

Earlier this month, Rotec Hydraulics completed a large project for a new customer who specialises in all aspects of confined space working from sewer rehabilitation, timber headings, tunnelling, grouting, all types of shaft sinking and associated clean and waste water works.

With a wealth of experience constructing shafts up to 30 metres in diameter and to depths of 35 metres, the specialist construction company sink shafts using various techniques – including hydraulically jacking segmental shafts vertically.

Rotec were asked to design, build and deliver ten hydraulic cylinders and two hydraulic power units (HPUs) capable of powering 40 tonne hydraulic jacks with up to 210 bar pressure for a significant shaft sinking project.

The HPUs operate ten hydraulic jacking cylinders using ten off detented levels and a single sprung loaded dead man’s lever. The jacking cylinders have a 160 bore, 110 rod, 1200 stroke and are mounted in frames which push down concrete segments to line holes. Each cylinder can provide up to 40 tonne force with 210 bar pressure which can be controlled by an adjustable knob on the HPU.

To speed up the extension and retraction of the cylinders, the HPUs have been designed with a two-stage pump which produces a faster flow when less hydraulic pressure is required. The pump is powered by a 7.5 kW 3-phase electric motor which is controlled by electrics mounted in an enclosure on each HPU. This allows the pump to be started and stopped easily, as well as providing essential emergency stop buttons.

Both HPUs have a 500 litre tank with pressure and return filters, in addition to a fitted level/temperature gauge. Connections from the HPUs to the cylinders are via protected hoses with quick release connectors.

To increase safety and reduce risk of harm to the operator, the hydraulic hoses on both the HPU and those to the hydraulic cylinders have been fitted with hose burst protection and whip checks where necessary.

Remote system fitted to quarry conveyor improves safety and operational control

100% Achilles audit _Rotec Hydraulics Ltd

Rotec Hydraulics have designed and installed a remote system, improving safety and operational control for our client at a significant limestone extraction quarry located within the South West of England.

Our customer utilises two tracked crawler vehicles to lift and manoeuvre a length of conveyor into position at the quarry. Previously, the vehicles had to be driven locally by personnel on the machine. To increase safety there was a request to design a system which would allow the machines to be operated remotely, keeping persons away from potential falling objects on the conveyor.

The remote system has additional benefits – including improving efficiency and the communication between machine operators because they can now stand next to each other and tandem lift with greater synchronisation. Previously they would be at opposite ends of the conveyor and this would require multiple banks-man and hand signals.

Rotec’s technical team and engineering team designed and fitted a new control system based around a Parker IQAN mobile specific safety controller which uses CAN Open protocol to safely communicate with a radio remote system.

Existing manually operated valves were exchanged for electronic proportional control, allowing the operator to drive all the hydraulic functions remotely that were previously only available using hydraulic levers locally on the vehicle.

Backup electronic joysticks have been installed locally on the vehicle if the remote control was ever to become damaged during use, eliminating the risk of the vehicle becoming stranded in this rare scenario.

Our customer requested we fitted their own specific blue warning lamps and white noise sounders, all of which are driven directly from the new safety controller.

The existing emergency stop system was removed and replaced with an updated dual channel fail safe circuit featuring safety relays, bringing the equipment up to modern safety standards. Emergency stops include one located on the remote control allowing the operator to stop functions quickly and safely from a distance.

The newly installed Rotec control system integrates with the existing engine controller to allow warning messages to be displayed on the screen located on the remote, providing the operator with ultimate feedback if any engine faults develop during use.

Rotec also installed a Bluetooth modem allowing the customer to make certain parameter changes to the control system using a free app that is available to download.

The app enables any user to view logs, check the health of the system and monitor various sensors all wirelessly from a smartphone or tablet. Additional features include the ability to connect the machine to the internet so Rotec staff can remotely assist, diagnose and install software updates if required. Password protection has been employed to prevent abuse of the system by anyone except personnel issued with the login credentials.

To integrate with the client’s corporate branding, we customised the remote control with the client’s logo. Customisations such as switch positions and labeling were also discussed and agreed with the customer before build to ensure we delivered the best customer service and client satisfaction.

100% Achilles audit _Rotec Hydraulics Ltd

Track and Manage Assets Worldwide

Parker Tracking System (PTS) is an innovative component-tagging and asset management solution offered by Rotec Hydraulics.

Record, manage and retrieve critical asset information with PTS.

This innovative system provides fast and accurate product information,
speeding replacement regardless of where or when the original component was created. Because tagged products can be replaced sight unseen, PTS eliminates the need to wait for removal before new parts can be acquired. Reducing transaction time means users can realize significant gains in productivity and equipment uptime.

Maintenance, Repair and Operations (MRO) can be greatly enhanced by customizing PTS and integrating it into existing systems. 

With seamless data integration, Parker enables bi-directional transfer of critical data to maximize asset visibility and performance. For details on supported platforms and protocols, contact a member of our team.

PTS works seamlessly around the world. Whether you sell, service or operate products and equipment in one city, one state or worldwide, PTS can be tailored to your needs. Equipment built in one country that is sold and serviced in another can use PTS to deliver accurate product details wherever and whenever they are needed.To support our global footprint, PTS offers translation in multiple languages.

For more information, download the PTS brochure here and get in touch with our Sales Team on 01823 348900 or email sales@rotec.net.

100% Achilles audit _Rotec Hydraulics Ltd

Rotec completes innovative remote monitoring system onboard a vessel

As equipment increases in complexity, there is a growing need and advantage to being able to monitor parts of, or a complete system remotely.

With a long held commitment to innovation, Rotec Hydraulics are the first known company in the UK to have designed, installed and commissioned Parker IoT software that remotely monitors a hydraulic system.

With the ability to be installed and remotely monitor any hydraulic system, Parker Internet of Things (IoT) technology allows a user to ensure their assets are working at full functionality by monitoring key performance indicators, such as temperature, pressure and flow.

The remote monitoring technology further benefits the user by providing vital performance feedback for preventative maintenance planning, and can monitor real time and historical data all within a simple web-based interface.

This web-based portal can be accessed worldwide and gives a further benefit of GPS asset tracking and visibility – thus aiding both security of equipment and logistical transport efficiency which in turn, can reduce fuel costs.

The innovative IoT project came to fruition following Rotec being asked by a boat manufacturer to gather information about the performance of the hydraulic system they were fitting to a new fleet of vessels. 

Because of the harsh marine environment, robust equipment was selected that meets high ingress protection. IoT modems are compact and have built in aerials allowing for a sealed solution, meeting strict IP67 ingress protection and wide temperature ranges of -30 to +75 degrees.

Multiple sensors were fitted by Rotec’s engineers to provide feedback of tank levels, oil temperatures, flows and pressures in various parts of the system.

A further enhancement was provided by adding a particle contamination device which monitors and uploads the vessel’s oil cleanliness data to the cloud. Previously hydraulic oil changes were performed on a time expiry basis, whereas adding sophistication of a real time oil contamination device now tells the customer when the oil needs to be changed rather than changing at estimated time intervals. This reduces both the cost for the customer and decreases the impact on the environment because they are now performed only when required.

The customer was particularly impressed as Rotec Hydraulics were able to code unique software and download this remotely to assist with additional logging during sea trials of the vessel before delivery for normal operations at sea. This provided additional information that has not previously been visible due to the nature of the testing preventing personnel being on board monitoring the systems from the bridge. 

The IoT can be connected to an engine ECU using standard j1939 CAN protocol to give live engine data to be able to monitor remotely. This can provide data feedback from various sensors to ensure optimal engine performance and critically, no abuse of the equipment when being used in the field.

Alerts can be set and configured to automatically send emails once thresholds are exceeded, enhancing the effectiveness of automated data upload. 

Built in Bluetooth and WiFi also allows the user to access the password protected modem locally to download logs and further enhance the remote experience. Software updates can be performed remotely over the web or by Bluetooth/WiFi to increase the functionality of the sampling controller or change data collection and upload frequency, allowing for maximum end user flexibility for the customer.

To discuss how Rotec can enhance your system monitoring, contact our Sales Team via 01823 348900 or email sales@rotec.net.