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 or phone 01823 348900.

Rotec Completes Machine Overhaul with the ‘Wow’ Factor

Rotec Hydraulics Ltd have delivered a machine refurbishment project with the ‘wow’ factor.

A leading manufacturer of high quality, precision tubes asked the Rotec team to assess and quote for the refurbishment of an old tube manipulation machine. The unit which had been in situ for many years, required a complete overhaul to improve efficiency and to provide quality and robust workmanship, due to regularly working with the toughest specifications in high performance alloys (including stainless steel, titanium and nickel alloys).

After removing the unit and transporting it to Rotec’s Plymouth service centre in Devon, the tube manipulation machine was stripped and inspected. Following the quoting process and being awarded the contract to proceed, Rotec’s skilled engineers carried out a thorough overhaul of the hydraulics, mechanical and electrical control system.

On completion, Rotec engineers attended the client’s site and re-commissioned the unit. All of the works carried out by Rotec were project managed by an assigned manager, as with all our projects. This allows for quality client-supplier relationships and improves communications.

Following the re-commissioning, the customer stated that they are very happy with the unit and they are impressed with the workmanship and quality of the overhaul.

Established in 1979, Rotec Hydraulics is a leading fluid power expert; providing quality design, build, installation and maintenance of hydraulic, pneumatic, electrical mechanical and electronic components and solutions to the Aerospace, Agriculture, Defence, Industrial, Marine, Transport and Utilities sectors throughout the UK and internationally. ISO 9001 and ISO 14001 certified, Rotec Hydraulics prides themselves on high operational standards.

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Rotec achieves Parker Certified Accumulator Service Centre recertification

100% Achilles audit _Rotec Hydraulics Ltd

Rotec is pleased to announce it has been re-certified as a Parker Hannifin Hydraulic Accumulator Service and Technology Centre.

Following successful completion of an audit process for Hydraulic Accumulator Technology and Service Centres, Rotec Hydraulics Ltd has retained its prestige as the only certified Parker Accumulator Service and Technology Centre in the South of the UK.

Parker Certified Accumulator Service Centres were established to enable the combination of industry-leading products with excellent customer service, and to deliver stress-free accumulator management with maximised performance, efficiency, and safety.

The benefits of being a Parker certified centre, in addition to Rotec’s status as a Parker Hydraulic Technology Centre, enables Rotec Hydraulics to provide integrated solutions that combine products, services and technologies. Rotec’s access to original spare parts provides tangible benefits to clients, including shorter inspection time and the reduction of complexity help to lower cost and to save time.

As added value to customers, the Rotec Hydraulics Ltd Service Centre is able to utilise the Parker Tracking System (PTS) which helps schedule accumulator maintenance, providing automated notifications on inspections and replacement parts.

Rotec Hydraulics have the knowledge, expertise and capabilities to deliver a comprehensive range of accumulator services including:

Regulatory compliance and certification

  • Hydraulic accumulator re-certification
  • Provision of tracking systems, data monitoring and recording
  • Optimising customer documentation to fulfil regulatory requirements
  • Local pressure vessel regulation
  • Audits, scheduled inspections and replacement parts

Hydraulic accumulator maintenance and pre-charging

  • Full service for just in time solutions and breakdown repairs
  • Full service for replacement and planned/preventative maintenance
  • Commissioning/testing (on-site)
  • Bladder and piston seal replacement
  • Gas pre-charge control and re-charge

System Optimisation

  • System design and improvement (including Hydraulic Power Units (HPUs) and Accumulator Racks, calculation, training and measurement)
  • Accumulator replacement

Asset Management

  • Energy and efficiency audits
  • Risk assessment and servicing of safety equipment
  • Asset condition monitoring and prognostics (sensors)
  • Legal conformity and insurance cover
  • Enabling customers to exploit the potential of Condition Monitoring and the use of Internet of Things (IoT) technology.

For more information on Rotec’s ramge of Accumulator services, contact our team.

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.

Rotec supports new immersive visitor experience at the Fleet Air Arm Museum

The Fleet Air Arm Museum will be wowing visitors with their new state-of-the-art, immersive Carrier Experience after a £1million refurbishment.

Rotec Hydraulics Ltd were pleased to carry out works on the hydraulic and electrical systems that are integral to the simulator experience at the museum, which houses aircraft and artefacts from the flying arm of the Royal Navy.

In addition to replacing over 50m of hydraulic hose, all hoses were uniquely identified using the Parker Hannifin PTS bar-code labelling system to ease traceability and future renewal. Rotec engineers also refurbished all hydraulic cylinders and repaired the two hydraulic pump units to ensure pressure and flow performance are maximised. Other works included replacement seals, filters and directional valves, strip and clean manifold assemblies and reservoir cleans.

Adjacent to the hydraulic works, Rotec carried out electrical works on the customer experience feature at the museum in the main pump room, remote control room and on the scissor lift which raises and lowers visitors during the simulation.

In the main pump room located control panel, Rotec removed existing obsolete Toshiba PLC unit hardware, and installed a newly supplied 24VDC 10A switch mode power supply module plus protective devices. A rewire the existing safety monitoring control relay and circuit was required to provide a dual channel redundant protective emergency stop circuit.

Rotec designed, supplied and installed replacement PLC hardware to replace the Toshiba module, which was then fully programmed with the required application specific logic code to ensure the scissor lift would rise and lower in time with the attraction’s audio-visual experience.

In the remote control room, Rotec supplied and installed an operator’s control station and local 24VDC power supply. The control station included a nominal 8” full colour touchscreen HMI device fully programmed with all existing and planned operator controls, indicators and alarms.

The works Rotec has completed in part of an overarching Carrier Experience. The new experience, which is dedicated to the memory of generous benefactor Vice Admiral Sir Donald Gosling KCVO, Vice Admiral of The United Kingdom, combines digital technology with the scale of a carrier flight deck to transport visitors from the pioneer years of the First World War, all the way to the modern HMS Queen Elizabeth class carriers of today.

Adam Gosling, of the Gosling Foundation comments,

“Vice Admiral Sir Donald Gosling KCVO, Vice Admiral of The United Kingdom founded the original Carrier Experience that opened in 1994 and has welcomed over four million visitors.


“To see the Experience reinvigorated and made meaningful and relevant for today’s audience is the perfect way to celebrate my late father’s enduring support of the Fleet Air Arm Museum. It reflects a mutual vision to preserve and showcase the proud history of British naval aviation. His generous legacy gift has enabled, once again, the illustrious tale of Britain’s aircraft carriers to be told, and enjoyed, for many more generations to come.”

Professor Dominic Tweddle, Director General of The National Museum of the Royal Navy says,

“The re-imagining of the Carrier Experience to include the Queen Elizabeth Class, the pride of the British fleet, demonstrates our ongoing commitment to the history of naval aviation and telling the story of the contemporary navy. This mix of heritage and modernity mirrors the projects that Vice Admiral Sir Donald Gosling KCVO, Vice Admiral of the United Kingdom so generously supported over the years.


“I am certain that the work of the staff team, contractors and corporate partner Lockheed Martin has brought to life the Carrier story in the way that Sir Donald had in mind when he made his legacy gift.  It is both an honour and a pleasure to recognise his lifelong support with this exhibition, which is housed in The Gosling Hall.”

Rotec were chosen to complete the works due to their impressive ability to combine hydraulics with complex electronic control systems. The works were completed in a matter of weeks, on schedule and to a high standard.

For further information on the expansive range of services Rotec offers, including case studies of other works, visit

Rotec deliver custom upgrade and HPU builds for leading manufacturer

Recently designed and manufactured, engineers at Rotec Hydraulics Ltd have completed a bespoke project for a market-leading manufacturer.

The British-based company specialise in the manufacture of electronic valve actuators for large fluid flow applications, for example within the oil and gas, water and power industries. The actuators produced are a considerable size and as such, part of the development process includes dynamic load testing. The actuators connect to a test cylinder via a screw thread; as the actuators move the screw thread up and down, this in turn pushes and pulls a hydraulic cylinder.

 Full of hydraulic fluid, the operators were manually operating needle valves to restrict the flow of the hydraulic fluid within the cylinders in order to vary the amount of load on the actuator. Thus, Rotec design engineers developed two key upgrades to this current setup which were:

  • Electrify the load control valves so they can be operated by a computer.
  • Create a power pack which can induce a given pressure inside the test cylinder bores.

 The newly custom-designed system reuses the current cylinders that vary in size from 63mm in diameter to 203mm. To accommodate for this, different sized stands with varying tank sizes have been manufactured to accommodate the extra capacity whilst the control components remain the same. The stands consist of:

  • A custom powder coated steel frame.
  • An aluminium reservoir.
  • Dual electronic proportional pressure relief valves.
  • Dual manual needle valves.
  • Dual ball valves.
  • Quick connect ports for the power pack to connect to.
  • Output ports which connect to the test cylinder.

In addition to this, Rotec developed and built three identical standalone hydraulic power unit (HPU) systems which can create steady state pressures inside the test cylinders bores to eradicate erroneous pressure lag errors. Features include:

  • Powder coated mild steel tank construction.
  • 3 phase motor coupled to a gear pump.
  • Air blast oil cooler.
  • Direction control valve.
  • Dual proportional relief valve.
  • Electronic control box.
  • Stainless steel tool tray.
  • Whole unit is mounted on castors for easy manoeuvrability.

For more information on Rotec’s capabilities, including project case studies, visit