Reliable Component Supply Enhances Productivity

100% Achilles audit _Rotec Hydraulics Ltd

As a company we at Rotec Hydraulics have worked alongside a gas turbine specialist providing them with a reliable supply of parts after a previous supplier let them down.

Rotec provides them with a range of products including; hose assemblies, pumps , valves , fittings and metal cutting compounds. The on-time delivery of these products enable the client’s  production line to run efficiently, reducing downtime and boosting productivity.

Rotec have assigned a dedicated account manager who holds regular review meetings with the customer to ensure their hydraulic requirements are met without fail.

The supply includes a number of Parker products. Parker, as the global leader of motion control products, are the gold standard for reliability and quality. As a leading distributer for Parker, Rotec is able to also bring a Parker representative to these meetings.

Rotec sales director Richard Lang comments,

“We are pleased to offer our OEM customers a reliable product supply service that enhances their productivity. We are committed to building long lasting working relationships with valued customers.”

If you are in need of a reliable product supply call 01823 348900 to discuss how Rotec Hydraulics can help you.

How Rotec Hydraulics Builds Smarter Systems with Parker IQAN Software

100% Achilles audit _Rotec Hydraulics Ltd
100% Achilles audit _Rotec Hydraulics Ltd

As a certified Parker distributor, Rotec Hydraulics is at the forefront of designing and building custom hydraulic systems that are not just powerful, but also smart. By integrating Parker’s IQAN electronic control system, we create solutions that enhance safety, boost efficiency, and provide unprecedented control over your equipment.

What is Parker IQAN and What are the Benefits?

Parker IQAN is a state-of-the-art electronic control system specifically designed for mobile hydraulic applications. It’s an integrated ecosystem of controllers, displays, joysticks, and sensors, all managed by a powerful and user-friendly software suite.

 The key benefit of IQAN is its ability to replace complex mechanical and electromechanical systems with a streamlined, totally electronic approach.

 Rotec has successfully designed, built, programmed and installed a variety of custom IQAN-enhanced systems. Clients have reported benefits including:

Enhanced Safety

IQAN controllers enable critical safety features like dual-channel fail-safe circuits and emergency stops which can be operated remotely. This enhances safety – keeping operators out of harm’s way, especially in hazardous environments such as quarries or construction sites.

Precision & Control

The software allows for precise, proportional control of hydraulic functions. Instead of simple on/off levers, operators can achieve infinite speed control and finely tune movements with joysticks and other input devices. This leads to more accurate and efficient operations.

Monitoring & Diagnostics

IQAN systems provide real-time monitoring and advanced diagnostics. The software logs events, and can alert operators to potential issues before they cause a breakdown. This proactive approach to maintenance dramatically reduces downtime and lowers repair costs.

Remote Accessibility

Rotec can build systems that allow for remote monitoring, diagnostics, and even software updates. This means operators can access the system’s data from a laptop or smartphone, diagnose a problem, and potentially resolve it without needing to be on-site.

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Customisation

IQAN software is flexible and user-programmable. Rotec Hydraulics’ in-house design team can customize the system to your specific needs, building in tailored functions, adjusting parameters, and creating a user interface on the display that is intuitive for your operators.

Why Choose Rotec?

By choosing Rotec Hydraulics, you’re not just getting a hydraulic system; you’re getting a complete, integrated solution. Our expertise in both hydraulic and electrical mechanical systems, combined with the power of Parker IQAN, allows us to:

  • Design and Build: Create bespoke hydraulic power units and control systems from the ground up, tailored to your application.
  • Install and Integrate: Seamlessly integrate new electronic controls with your existing machinery, replacing outdated components with modern, smart technology.
  • Provide Ongoing Support: Offer remote diagnostics, software updates, and expert maintenance to ensure your system continues to run at peak performance.

Examples of Rotec-designed IQAN systems include a remote control system built for a quarry, which enabled operators to control heavy machinery from a safe distance, drastically improving safety and efficiency. Another project involved the development of a pioneering electric winch system, where Parker IQAN technology was instrumental in achieving precise proportional speed control – a function previously thought impossible for an electric system.

For more information, request a discussion with a member of our Sales Team via sales@rotec.net.

Modernising Ramp Actuators

Mitigating obsolescence and ensuring long-term operational efficiency. 

100% Achilles audit _Rotec Hydraulics Ltd

The Challenge: Aging, proprietary ramp actuators (50+ years old) posed maintenance and obsolescence risks, with strict dimensional constraints for replacement.

The Solution: A bespoke engineering solution, developed in collaboration with Landau UK Limited, which delivers a high-performance, modernised replacement using readily available components – reducing obsolescence risks, and extending the serviceable lifespan of the unit.

Key Design Requirements: The new jack was engineered to meet the following critical performance and operational specifications:

  • High Force Capacity (Max pull force: 61,000 kg, max push force: 81,300 kg)
  • Compact Dimensions
  • Fluid Compatibility
  • Weight Optimisation and Manual Handling (Weight reduced from previous jack)
  • Self-Contained System (Integrated design for autonomous operation)
  • Single control interface for intuitive control
  • Manual Backup
  • Over-Pressurization Protection
  • Robust exterior for handling resilience
  • Environmental durability (temp range from -30°C to 48°C, direct saltwater environment)

Manufacturing and Component Strategy: Modern CNC machining techniques employed for manufacturing. Non-machined components, such as o-rings, rod seals, bearings, and fixings, were selected as commercially available products to ensure long-term accessibility.

Testing and Validation: Rigorous factory acceptance testing, utilising a custom 160+ tonne capacity test frame, validated performance under maximum loads.

Delivery and Packaging: Units packaged to stringent Level N Defstan requirements for secure storage and transport.

Outcome: Six units delivered ahead of schedule and fully compliant.

The modernisation provides a sustainable, maintainable solution, mitigating obsolescence and ensuring long-term operational efficiency.

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.

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.