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.

Rotec Hydraulics Set to Exhibit at Seawork 2025

Rotec Hydraulics Ltd, a leading provider of hydraulic, pneumatic, and electrical mechanical solutions, is pleased to announce its participation as an exhibitor at this year’s Seawork, Europe’s largest on-water commercial marine and workboat exhibition. The event will take place from 10th to 12th June 2025, at Mayflower Park in Southampton, UK.

Our team will be on Stand G38 showcasing Rotec’s comprehensive range of products and services tailored for the marine sector – with a particular emphasis on how to work smarter, reducing costs, whilst maximising performance and uptime.

With over 40 years of experience, Rotec is renowned for its expertise in the design, build, supply, installation, and maintenance of fluid power and motion control systems.

Visitors to the Rotec Hydraulics stand will have the opportunity to explore:

  • Bespoke Hydraulic and Pneumatic Systems: Discover Rotec’s capabilities in designing and manufacturing custom power units, flushing rigs, and complex system integrations to meet specific marine requirements.
  • Electrical Mechanical Services (EMS): Learn about their comprehensive EMS offerings, including motor, alternator, generator overhauls, vital for marine vessel operations.
  • PTS (Parker Tracking System): a barcode system that allows you to track assets worldwide and easily order replacements via a web based platform.
  • IQAN: cutting-edge technology allowing for the monitoring and enhancing electrical control systems using the power of IoT.
  • Component Supply: Explore Rotec’s vast stock of high-quality hydraulic and pneumatic components from leading brands such as Parker, Galtech, Heypac, and many more. Their team will be on hand to provide expert advice and technical support.
  • Accumulator Servicing & Parts: Gain insights into stress-free accumulator management and PSSR compliance.
  • OEM Kitting Service: See how Rotec’s custom multi-component kits and hose assemblies can streamline manufacturing processes and improve productivity.

The Rotec team will be available to discuss current projects, offer technical guidance, and explore potential collaborations with industry professionals.

“Seawork is a great event for the commercial marine industry, and we are delighted to be exhibiting again this year,”

says Richard Lang, Sales Director.

“It provides an invaluable platform to connect with our existing clients, forge new relationships, and demonstrate our commitment to delivering innovative and reliable solutions to the marine sector. We look forward to engaging with visitors and showcasing how Rotec can support your operations.”

Rotec invites all attendees to visit their stand at G38, Seawork 2025 to learn more about their capabilities and how they can assist with all fluid power and motion control needs in the marine industry.

Register to attend at: Seawork 2025

100% Achilles audit _Rotec Hydraulics Ltd

Rotec joins Cornwall Marine Network

Rotec Hydraulics Ltd is pleased to be announced as the Cornwall Marine Network’s newest member.

By joining the Cornwall Marine Network and operating from our Falmouth Service Centre, we are strengthening our on-the-ground support for the county’s world-class marine industry.

Building on our existing strong relationships with Cornish customers, our new Falmouth Service Centre, positioned within Falmouth Docks, enables us to offer even greater local support. Our team’s extensive expertise across hydraulic, pneumatic, and electro-mechanical disciplines ensures we can provide comprehensive solutions tailored to the unique demands of the marine sector and beyond.

Heading our Falmouth operation is Martin Webber, whose 25+ years of experience in the marine and shore-based energy sectors bring invaluable industry knowledge and a dedicated passion to our local presence. Martin will be instrumental in forging stronger relationships with businesses throughout Cornwall.

As an ISO 9001 and ISO 14001 certified company, Rotec Hydraulics Ltd maintains the highest standards of quality and environmental responsibility. We offer a comprehensive suite of services, from initial design and installation to ongoing maintenance, repairs, and component supply, providing end-to-end support for our clients.

We understand the specific challenges faced by businesses operating in the marine environment. Our aim is to deliver reliable, efficient, and cost-effective solutions that ensure seamless operational continuity.

We are eager to collaborate with fellow members of the Cornwall Marine Network and contribute to the region’s thriving maritime sector.

To learn more about how Rotec Hydraulics Ltd can support your business, please get in touch via falmouth@rotec.net or phone 01326 653 287.

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.

 

Hydraulic fuel system with integrated pipework solutions carried out by Rotec

Rotec engineers have carried out integration and commissioning of a hydraulic fuel system with pipework solutions on a brand new vessel for a prestigious boatbuilder.

After being let down by another supplier, the client requested Rotec to carry out the works following referrals made by others within the Marine industry who had given Rotec glowing reviews.

A reliable and efficient hydraulic fuel system, built with quality components, aids any vessel engine to run smoothly, avoid unexpected engine failures and ensure passenger safety. Additionally, built and maintained to a high standard, a hydraulic fuel system will be compliant with good practice and environmental regulations.

Rotec’s engineers, whose skills and experience span across multiple engineering disciplines – from hydraulics to electrical – installed and commissioned the hydraulic fuel system in line with the boatbuilder’s schedule of works.

The hydraulic tank design supports 2 hydraulic pumps, driven by 2 engines. The flow rate from each pump (45cc per rev) is estimated at a max 70LPM. The system also supports 2 thrusters, coolers and LS lines.

All pipework solutions used 50mm and 25mm stainless tube with 1.5mm wall thickness. This reduced the number of joints, whilst providing good circulation. Pipework materials centring on the use of rigid tube within the engine machinery space and completion of service points with flexible were employed where required. Finally, pipework was cleaned utilising the pelleting system and flushed.

All hoses were supplied by Rotec and supported by the Parker Tracking System (PTS). This labelling scheme enables a user to quickly scan any asset using a non-subscription, free mobile app. The asset’s technical specifications, including part number are then displayed, enabling efficient and accurate re-ordering of parts when required. App users can also set up service alerts to notify them of when a part’s lifespan is coming to an end.

For more information regarding Rotec’s capabilities, visit www.rotec.net. 

Multi-million pound refurbishment of MS Bolette unveiled

Supported by Rotec’s electrical mechanical services team, a multi-million pound refurbishment of MS Bolette has been unveiled to CLIA and Government officials.

The Bolette entered dry dock for a 13-day refurbishment, including maintenance to the ship’s Azipods and bow thrusters as well a new application of anti-fouling paint. Rotec Hydraulics Ltd, based across the South West of the UK, were responsible for the overhaul of Bolette’s eight thruster fans.

After the fans were electronically and mechanically disconnected, the vessel’s thruster fans were transported by Rotec for a full inspection. Following the inspection of all plate detail and insulation valves, the fans underwent dynamic balancing. The units were then transported back to the shipyard and reconnected, with a full works report supplied to the client.

The turnaround for the project was a mere 8 days from the ship arriving in the UK shipyard to Bolette setting sail again on 7th March. To ensure the tight deadline was met, Rotec engineers went above and beyond, working a 24/7 split shift pattern. Unplanned and additional emergent works which occurred, were quickly responded to by the Rotec team. Following the works, Mark Terrell, Electrical & Maintenance Manager at A&P Falmouth commented on Rotec’s service delivery:

“I would like to take the opportunity to thank you for the support. The Rotec response was great and by Monday 16:00 (less than 24 hours later) the ship had passed off all 8 fans as complete and ready to return to service. Special mention must go to [your engineers] for sticking with the job through Sunday night and well into Monday!”

MS Bolette has now sailed to Newcastle to complete its spring/summer season operating in Europe. Owned and operated by Fred. Olsen Cruise Lines, Bolette was formerly named Amsterdam and was the last ship of the four Rotterdam class (R class) cruise vessels.

For more information on Rotec’s Electrical Mechanical Services visit www.rotec.net.

 

Image: Aerial view of A&P Falmouth, where refurbishment of MS Bolette took place. Image source: https://www.cruiseandferry.net/