Hydraulic Systems

Hydraulic systems can be found everywhere, from: food production lines and material handling to credit card manufacturing, waste management and recycling, transport and logistics, and those fairground rides that you love – or hate – the list goes on and on…

Add to that the fact that our customers come from all four corners of the world, all walks of life and industry, and with ideas and requirements great and small, there’s just never a dull moment here – that’s why we love what we do and as an ISO 9001 accredited company are passionate about doing it well. Every time.

We don’t simply “sell” hydraulic systems – we can’t, there’s no one-size-fits-all solution. Instead we make it our business to understand your business… your needs, your priorities and constraints, and then work with you to develop the hydraulic systems solution that’s right for you. And with the  technical team’s 60 years combined experience in hydraulic systems design, we can assure you that no idea is too big or too small – or too crazy! We’ve dealt with some of the toughest hydraulic systems design challenges, but we’re yet to be outdone!

Mark has been a star getting the kit together for a relatively crazy idea I have for an accessory which could have commercial applications beyond us… I’m a relative hydraulic ignoramus and he explained the options brilliantly to me.

It doesn’t matter if your idea isn’t nailed down yet; all we really need is for you to be able to define your end goal. What is it that you want to move, raise, lower, shift, compress, turn, (you get the idea)… how quickly and how often? The team can then show you the best way to get there and we’ll support you all the way through to final production and beyond.

Here are some hydraulic systems we “prepared earlier”…

A UK steel works contacted Hydraulics Online asking us to provide a complete, new hydraulic system capable of moving a 7000kg tool slide in a controlled and timed “stop-start” movement, and also to lift and lock the associated mandrils as required in a continuous cycle.

Hydraulics Online designed a complete bespoke hydraulic system proposing improvements to the customer’s original design and incorporating proportional valve control of the 100 litre/minute and 80 litre / minute pumps that were fitted to the power pack. The complete system was manufactured, installed and commissioned without a hitch!

Moving on from steel to plastic… our engineers were called to the site of a high quality credit, debit and store card manufacturer to fault-find a critical piece of hydraulic equipment and provide a timely solution to production problems. An off-line compatible high pressure (700 bar) hydraulic system was sourced and installed enabling the customer to meet production targets within agreed deadlines and service levels… thus avoiding severe third-party penalties!

There’s more! Our technical team were tasked by a power transmission equipment manufacturer and wholesaler to provide a complete hydraulic system and hydraulic cylinder for a tipping hopper application.

Hydraulics Online specified, designed and supplied a complete hydraulic system including hydraulic power pack and hydraulic actuator. Hydraulic cylinders and mounts were made according to the customer’s specification and the whole package was delivered within budget and time constraints… because we don’t make promises that we can’t keep.

One of our most famous hydraulic systems customers, that we can tell you about anyway, has to be Concorde…

Concorde hydraulic systemsThe team were asked if we could help with a project involving Concorde G-AXDN, on display at the Imperial War Museum, to make her the first Concorde in the UK to have a fully functioning droop nose and visor. And the rest, as they say, is history. You can read all about this exciting project here.

I am extremely pleased to have met such a good team who have supported Concorde and Heritage Concorde so well… you deserve a medal! I was amazed; you reeled off figures and technical data that were way above my understanding, but explained things very well. You don’t just shift boxes; you know your business inside and out. A very big “thank you” from the whole team –  I hope we can continue the great work.

Hydraulic ManufacturersIf you’re happy that your hydraulic systems design is already sorted, then maybe we can help by supplying the equipment and components that are needed to bring it to life. We have access to an extensive range of hydraulic manufacturers from around the world, and can often offer high quality, direct equivalents to big name brands; useful if you need to make your budget stretch that little bit further or have somewhat challenging deadlines to meet!

Our technical team have over 60 years’ experience between them, and are regularly credited with the fact that they “really know their stuff”. They love talking hydraulics too, so whether you would like to talk hydraulic systems or equipment then call us on: +44 (0) 845 644 3640. Our offices are in the UK, so if you’re here outside of our office hours (8:30am to 5:30pm Monday to Thursday and until 4:00pm on Friday) then you can reach us via:sales@hydraulicsonline.com through our online chat (even when we’re offline you can send a message) or by completing our online enquiry form.

System Hydraulics

Whether you’re starting with a blank sheet of paper or you are trying to improve an existing hydraulic system design, we understand that you’ll need performance efficiency and availability of components to make it work. Our team here at Hydraulics Online have over 60 years combined experience in hydraulic system design and supplying components, so there’s no need to worry. Your brand is in safe hands.

“Hydraulics Online… fast, friendly and competitive but we value them most because they are innovative and can find answers to the really tough hydraulic design problems.”

Our hydraulic engineers will help you through the entire process of your hydraulic system design, from outlining costing through to the final production of your hydraulic system. As an ISO 9001 accredited company, we believe that you should only get the best service and hydraulic equipment for your hydraulic system – and it could save you money in the process. As most of our popular hydraulic components are directly interchangeable with other lesser-known manufacturers, the possibilities are endless.

To bring this to life a little bit, following a search on the internet, a shredding and data disposal company contacted Hydraulics Online asking us to design and supply an efficient hydraulic system to run a mobile compactor and crusher.

Hydraulics Online proposed a hydraulic system using Italgroup radial piston motors. The vehicle was delivered to Hydraulics Online’s premises and our hydraulic engineer installed the PTO driven power source and hydraulic control valves. A second vehicle has since been fitted out to the same specification.

Another example of our work, after being approached by a leading producer of concrete products to civil engineering, construction and agricultural sectors, Hydraulics Online were tasked with replicating an existing, ageing hydraulic system that was no longer available.

The Hydraulics Online design team worked with absolutely minimal information and proposed a much more modern and efficient hydraulic system. This enabled the customer to order and install multiple sets of hydraulic equipment with major cost savings being realised in the process.

Finally, a leading manufacturer of concrete products requested Hydraulics Online to design a complete hydraulic system that would meet the customer’s exact requirements.

A full hydraulic system was designed and supplied comprising single-acting, telescopic lift cylinders and complete power pack. It was successfully installed and commissioned and is now in use in daily production.

As a trusted supplier, we have extensive competitive access to many popular and niche hydraulic manufacturers… you can find out more about them by clicking here.

Don’t just take our word for it… visit our testimonials page here. To find out more about the kinds of products we provide, visit our website. And don’t worry if you’re not sure on what sort of hydraulic component you need; our experienced team can help determine the one that will be best suited to your application. You can email sales@hydraulicsonline.com or you can speak to one of our friendly team members: +44 (0)845 644 3640.

Hydraulic Lift

If it’s hydraulic, then in the words of our customers we “know our stuff”. But knowledge isn’t enough, and right from the outset, we have always believed in consistently delivering first class customer service too – hence our investment to achieve ISO 9001 Quality Management accreditation through the British Standards Institution.

Over the years, the feedback from our growing customer base has always been that we are doing things right, doing things well… Doing what we say we are going to do. We regularly receive “thank you” notes and emails from our customers, who want to recognise our commitment to customer service. This email, received today, needs no further introduction…

I needed to repair a Chiltern Concept 2000 bath system for a wheelchair user… The bath was generally in very good order, although the hydraulic lifting mechanism had developed a fault that would occasionally leave the user stranded in the bath or part way out.

On close examination I found that the hydraulic lift system was based on a Smiths Industries hydraulics company power pack and ram, but there were no obvious signs of hydraulic oil leakage.  I discovered that the original company had gone into liquidation and the new company,  Chiltern Invadex, were unable to support this bath.  The situation was made yet more complicated as the hydraulic components were no longer available as replacement parts.  The only option seemed to be to install a new bath and hydraulic lift at considerable cost.

In a desperate attempt to save costs and quickly restore the bath to working order, I contacted Hydraulics Online.  Mark Tonks, the Managing Director could not have been more helpful.  He suggested returning the power pack and ram to their works in Alsager, Cheshire, where they would test all components.  

I am delighted to say that they discovered the faulty component, replaced it and shipped the items back to me in West London. After reinstalling the hydraulic lift mechanism the wheelchair user now has a fully functional hydraulic bath. It has now been operating perfectly for the last 3 weeks.  

The service provided by Hydraulics Online was exceptional.

Doctor M.R.T.


Your one-stop hydraulic resource…

Thanks to our seemingly unrivalled access to a vast range of hydraulic manufacturers from around the world, and our innovative approach to hydraulic problem solving, Hydraulics Online are THE hydraulic supplier that a rapidly increasing number of customers turn to for all their hydraulic equipment and systems design needs.

Large and small alike, our customers frequently rationalise their existing hydraulic supplier base, knowing that the team here can be relied upon to deliver trusted advice and solutions… backed up by reliable deliveries of hydraulic equipment from both well-known and niche hydraulic manufacturers. Hydraulic equipment that, in the nicest possible sense, they can then just “fit and forget”.

Not only that, but our team are fast gaining a reputation for loving a challenge. Straight forward and easy can be boring, right? We like to be kept on our toes. We are regularly tasked with sourcing seemingly obsolete or discontinued hydraulic components and haven’t been beaten yet. Often working to the tightest of budgets and delivering “yesterday”, if an original product isn’t available, or lead times are unworkable, we can offer a direct equivalent or re-manufactured unit.

We like to say that…

If it’s hydraulic we can design it, supply it, solve it or repair it!

That includes: hydraulic pumps, hydraulic motors, hydraulic power packs and units, hydraulic cylinders and rams, hydraulic valves, hydraulic filters and filtration systems, hydraulic accumulators, and hydraulic coolers and accessories for any kind of application in any kind of market – even ATEX rated hydraulic equipment .

As an ISO 9001 accredited business, we don’t just “sell” hydraulics however… unless that’s all you want us to do. We aim to make it our business to understand your business, so that we can be certain we can give you the best hydraulic advice possible and recommend products that really are “fit for purpose”.

Technical advice and assistance was first class and we would not hesitate in contacting you in the future to satisfy our requirements.

So even if you’re not sure what hydraulic product you’re looking for… Let us take the pressure!

It goes without saying that we love all things hydraulic. And, keen as we are to spread the joy and understanding of hydraulic engineering, and believing that prevention is always better than cure we have produced what we hope you will agree is a useful hydraulic reference section.

We add to this on a regular basis but, if you click on the links here you can find:

And finally, based firmly on the belief that prevention is better than cure we have some hints, tips and trouble-shooting guidance for you.

Hydraulics CatalogueWe have never tried, or even thought about trying, to measure the scale of our hydraulic product offering – the number is, however, unquestionably huge! Our online catalogue showcases a very small selection of the products that we supply – we couldn’t possibly squeeze everything that we do in here!

If you’ve read this far and haven’t found or seen mention of the information that you’re looking for then there’s plenty more to see by clicking around on the menu above. But as you’ve no doubt gathered, there’s a lot that can be written about hydraulics – so if you’d rather just talk to one of the team instead, we’d love to hear from you.

Testimonial: 12vDC Mini Hydraulic Power Packs

 Hi Mark,

That is spot on. Thanks for all your help, its great knowing we have someone like you supporting us on  these types of  vehicles.

This was the feedback emailed in earlier today from a happy customer; a leading designer and manufacturer of customised specialist vehicles and exhibition units used in: film and TV production, music festivals, live sports events and promotional roadshows.

At Hydraulics Online we don’t believe in just taking orders, unless that’s all our customers genuinely want and need us to do. Instead we make it our business to understand your business… asking the “right” questions about your application… often leading to a more robust, efficient, safer and cost-effective design in the process.

12vdc mini hydraulic power packSo, whether you are looking for a relatively standard 12vDC mini hydraulic power pack, or a completely bespoke unit, then you have come to the right place. If a “relatively standard”, but still customisable, hydraulic power pack is what you’re looking for then as an authorised distributor for UK-based Fluidlink Hydraulics we offer a comprehensive industry-standard hydraulic power pack range, including the former Smiths Industries power packs. Widely used in industrial and mobile applications, the Fluidlink hydraulic power pack range is available in AC and DC and with three different versions of body and tank to choose from a hydraulic power pack can be readily customised to meet your own specific requirements.In this particular case case our customer will be taking delivery of a number of 12vDC mini hydraulic power packs complete with start switches.

Hydraulics CatalogueClick here to hop over to our catalogue and view our range of standard, mini and micro Fluidlink hydraulic power packs. If you can’t find the hydraulic power pack that you’re looking for then complete our stock enquiry form, or for more technical advice and hydraulic power pack quotations contact one of our team on: 0845 644 3640, or via: sales@hydraulicsonline.com

240v Hydraulic Power Packs

It’s no secret that we love hydraulics. The vast range of applications that we’re always involved with means that no two days are the same, and there’s certainly never a dull moment knowing that we’re very much involved in “keeping the wheels turning” all over world. In fact, at times we’re making the wheels do more than just turn…

The hydraulic power packs pictured here were made to order for a new customer; a specialist leisure ride design and manufacturing company whose product range extends from monorails and roller coasters to water rides and  lifts. See! Hydraulics are fun too!

In this instance, the Hydraulics Online team were approached for technical support on a new roller coaster design project. The bespoke mini hydraulic power packs (3 of 20) here are to be powered by 0.55kW, 240vAC single phase cap start – cap run motors, complete with additional pressure-line switch operating between 20-200 bar. The design also called for double-acting cylinders (25mm bore, 16mm rod, 250mm stroke) which are also pictured here.

Whether you are looking for a relatively standard 240v hydraulic power pack, want to improve the performance of your existing system or are looking for a bespoke (240v) hydraulic power pack as part of a larger hydraulic systems design project then look no further. We can help.

Hydraulics CatalogueYou can click through to our hydraulic power pack gallery to see examples of our work to date or hop over to our catalogue and view our range of standard, mini and micro Fluidlink hydraulic power packs.

Case Study: Hydraulic Power Packs for Specialist Vehicles

Supporting customers’ new product development activities and delivering tender-winning solutions is all in a day’s work for the technical team here at Hydraulics Online. Our philosophy is one of not just “taking orders”, unless that’s all that our customers want and need us to do. Instead, we make it our business to understand your business… only then can we be sure that we are supplying you with hydraulic equipment that really is “fit for purpose”. Unfortunately, not everyone shares this way of thinking.

A global specialist vehicle converter, contacted the technical team recently looking for support having been let down by their existing supplier. They had previously taken delivery of a hydraulic power pack that had been incorrectly specified and was simply not suitable for their application; their successful tender for a major new contract was at stake.

Having asked the “right” questions and gathered as much information as they could about the application and its operating parameters, the technical team proposed an alternative system and suggested some additional improvements and safety features that could be made to the design.

Within the week the customer received their hydraulic power pack and additional equipment, and shortly afterwards began to put it through its paces as the prototype platform lift of a commercial vehicle. It worked a treat. The customer then placed an additional order to to enable them to implement our earlier recommendations for additional systems improvements… and we are delighted to say that they won the tender!

So whether you are looking for a relatively standard hydraulic power pack, or a bespoke unit as part of a larger hydraulic systems design project then you’ve come to the right place. You can find out more about the different types of hydraulic power unit here or…

Catalogue LogoClick here to hop over to our catalogue and view our range of standard, mini and micro hydraulic power packs. If you can’t find the hydraulic power pack that you’re looking for then complete our stock enquiry form, or for more technical advice and hydraulic power pack quotations then please contact one of our team

Case Study: Hydraulic Power Pack Design

It’s no secret that we love hydraulics, and the absolute vast array of applications and projects that we are involved with every day. Take our hydraulic power pack design services – one week we’re designing the system to make the first UK Concorde “droop nose” work again and the next we’re working on a project to make mud bricks in Africa…

A new customer approached the technical team with a proposed design for a machine to make mud bricks to aid the construction of huts and basic housing in Africa; the whole project was being funded by a local charity/welfare group. The purpose of the machine was to compress the mud in large, brick-shaped moulds before the bricks were then baked and used to build the huts.

Drawing on their extensive technical knowledge, our technical team suggested some modifications to the customer’s original suggestions and then went on to build a hydraulic power pack design that would meet the system requirements exactly.

The picture above shows the complete machine and the hydraulic power pack in situ and below we have a “thank you” from the customer:

“Thanks for all your support and your prompt replies to my queries and for providing the best hydraulic power pack design and equipment… unlike the substandard components from China used by others. Our client is very happy with the overall performance of the equipment.”

Concorde HydraulicsSo whether you’re working on Concorde or just working with mud you can rely on Hydraulics Online to design it, supply it, solve it or repair it!

Case Study: Hydraulic Power Packs for OEMs

It’s a small world at Hydraulics Online – whether delivering our products to customers locally or to customers abroad, we can take the pressure!

We recently had an enquiry from an original equipment manufacturer (OEM) in New Zealand; the company were looking for a hydraulic power pack manufacturer in the UK… to provide a quality, British product. The team at Hydraulics Online have a wealth of experience in building and supplying hydraulic power packs, so we knew exactly what design and specification would work best in the customer’s application (a single-acting, 12v DC hydraulic power pack with flow control) and were able to quote instantly. The customer requested a trial power pack, which we proceeded to build and ship the same day.

After being put through a period of very rigorous testing over a number of weeks, the power pack had more than proved itself… delivering the performance that our OEM was looking for as a key component within his product. As far as an OEM is concerned, having peace of mind and being able to “fit and forget” hydraulic components is clearly vital.

Single-acting 12v DC hydraulic power packWe’re delighted to say that a further ten hydraulic power packs were shipped to New Zealand last week, the first of many given that our hydraulic equipment is now an integral part of this OEM’s core product design…  Proof that here at Hydraulics Online, we really do understand the importance of increasing the value of an OEM’s brand and product range. Every project we work on is scrutinized to ensure a successful design and ongoing cost-effective manufacturing, using components that truly are “fit for purpose”.

“We approached Hydraulics Online 18 months ago for assistance in the design and supply of bespoke hydraulic control systems. As a result of their vast technical knowledge and wide product range available, we were able to develop a system which was both competitively priced and completely tailored to suit our application.

Since our initial projects with Hydraulics Online, we have worked together to develop further systems to complement our product range, further heightening our position in the market place. They have also been a valuable technical partner assisting our engineering personnel on site with issues faced in the field. Overall, a valuable tool for any business.” – An appraisal from another satisfied OEM customer.

Case Study: First UK Concorde Droop Nose

The hydraulic systems on Concorde 101 G-AXDN had not been used since she was retired in 1977, but with the technical support of Hydraulics Online a plan was created to bring them back to life…

Duxford Aviation Society, owners of the British Airliner Collection, were keen to improve their display of Concorde 101 G-AXDN at the Imperial War Museum. In response, Heritage Concorde proposed making her the first UK Concorde since 2003 to be able to “droop” her nose… and then approached Hydraulics Online asking if we could help on “Project Salute” – we certainly could!

The nose was last lowered in the 1980’s using the emergency free fall system after an attempt to use the aircraft’s hydraulic system had failed. Whilst there was clear support for the latest project there was also, therefore, a great deal of concern and considerable work involved in ensuring that there would be no damage to G-AXDN and that all Health & Safety requirements would be met.

Heritage Concorde provided our team with the technical specification for the Concorde nose systems and then undertook the preparatory work needed to inspect the associated aircraft wiring and nose/visor control systems. The nose is operated by two hydraulic systems – green being the normal and yellow the standby; only the normal system was to be used, in isolation from all of the other hydraulic systems on the aircraft.

Concorde Power PackHydraulics Online designed and built a bespoke hydraulic power pack that could be connected to the existing nose hydraulic systems and allow the visor and nose to be lowered and raised at any time; safety features included a pressure gauge and a hydraulic pressure valve. Meanwhile the Heritage Concorde team began the painstaking task of cleaning and preparing the existing nose systems and mechanism and examining the electrical controls for the nose within the cockpit.

The hydraulic power pack was put through a number of rigorous tests before it was connected to the nose system; once installed, the specialist hydraulic mineral oil was added, before bleeding and flushing the system through to remove any remaining debris.

Heritage Concorde TeamHaving been idle for so long, the aircraft hydraulic systems needed to be fully cleaned. After 18 months the project was successfully completed; G-AXDN is now the only Concorde in the UK with an operational nose and visor. Graham Cahill, Director of Projects at Heritage Concorde (pictured centre) commented: “It has been a real pleasure dealing with the team at Hydraulics Online; they have been very accommodating throughout the project, giving expert advice and technical support… We really couldn’t have asked for more.”

David Garside, Chairman of Duxford Aviation Society, unveiled G-AXDN’s droop nose at the Imperial War Museum, Duxford on 24th October, 2014 – timed to coincide with, and “Salute”, the 11th anniversary of the last commercial flight by Concorde. He added: “It is 37 years since Concorde G-AXDN was flown to Duxford and since the hydraulic and electrical systems were last in operation. The restoration projects have required the servicing and overhaul of many intricate components and considerable patience and determination has been required over a two year period to ensure their successful completion… We gratefully acknowledge the generous sponsorship and support from Hydraulics Online Ltd and for designing and supplying the hydraulic power pack.”

Mark Tonks and David Garside

Mark Tonks, Managing Director of Hydraulics Online Ltd said: “We were absolutely thrilled when Heritage Concorde asked if we could help on “Project Salute”. Our customer base is global, we’re always involved with a vast range of projects and systems design work and we deal with some big household names… but Concorde is in a different league. Seeing G-AXDN’s nose and visor moving again, knowing that we were part of the team that made it happen, is very special indeed.”

The unveiling of Concorde G-AXDN and her droop nose made the headlines and was featured on the BBC News and ITV News as well as being reported on by local and regional press.

Why not go and visit Concorde 101 G-AXDN and see her amazing droop nose and visor for yourself? Click here for opening times and directions to the Imperial War Museum, DuxfordIn the meantime, you can see footage of the nose and visor moving here: Video clip one and video clip two

If you haven’t seen it already you can read our Introduction to Concorde, but if you would like more technical information then the following links provide further details on the:

Blog & Case Studies

International Hydraulics – Ain’t no Mountain High Enough!

Here at Hydraulics Online we always like to go the

June 13, 2017 read more

News Archive

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