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“Infinite cylinder” upgrades lumber logistics p. 24

er b m e t p e S show e coverags begein48

Evolution of hose crimping p. 36

Lubricants improve profitability, productivity p. 42

August 2021


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FLUIDLINES Mary C. Gannon • Editor

Getting smaller and bigger all at once Lately, it seems a month doesn’t go by where I’m not receiving some news about a merger and acquisition in the industry. Sometimes, it’s one small distributor or repair shop acquiring another to expand their reach. And others, it is the big players getting even bigger. Unless you’ve been living under a rock the past year, you clearly have seen the news about the Danfoss-Eaton merger being fully approved this month. Here, we see one of the oldest hydraulics companies in the U.S. selling off its hydraulics business because it was not clearing the profit margins Eaton wanted. On the other hand, you have Danfoss, who just secured itself as one of the largest fluid power suppliers out there, growing by onethird and doubling the company’s hydraulics operations. One company dumps what it considers a low-growth business while another sees a brighter future. Eaton Corp. still exists but no longer as a major hydraulics supplier — the company retained its Filtration and Golf Grip divisions. (While we’re at it, how are golf grips a fluid power division in the first place? That predates my work in the industry.) Funnily enough, on the exact same day Danfoss and Eaton’s deal closed, Parker Hannifin announced it would acquire British aerospace and motion control giant Meggitt for 6.3 million pounds (interestingly, another U.S. buyer has emerged luring Meggitt with 7.03 billion, so this is clearly not a done deal). Of note in this deal, however, is that Meggitt has no fluid power footprint at all — showing Parker, too, sees the need to expand its own footprint into what some may consider a more profitable area outside of fluid power. The deal would nearly double Parker’s Aerospace Systems Segment with complementary technologies. Parker is known for growing its business through acquisitions. However, the last fluid power acquisition the company made was in 2017, when it acquired Helac Corp. What does this mean for the industry? The number of players in the industry continue to shrink, just as the bigger players keep getting bigger. While this will allow Danfoss and Parker to invest in more product development, there is less competition. And competition drives innovation. But that doesn’t mean we have to stop innovating. Danfoss is committed to electrification, and their innovations in this area may be key to their future. Danfoss is also investing in autonomous vehicle research, and those two technological innovations could be the future of mobile machinery. And perhaps Parker will leverage Meggitt’s electromechanical motion control expertise to expand its own electrification expertise. These big moves by the big players open the door for continued investment in that area. So while our industry keeps getting smaller by number of manufacturers, perhaps we’ll get bigger by building out new technology focuses. FPW

Mary C. Gannon • Editor On Twitter @DW_marygannon



8 • 2021


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FROM THE FIELD Paul J. Heney • VP, Editorial Director

How are you going to 2030-proof yourself? Recently, I made it out to the NAHAD Annual Convention in sunny Scottsdale, Ariz., for a few days of learning and networking with wonderful manufacturers and distributors in the hose portion of our industry. It was fantastic to get on the road once again, and I’m looking forward to many more productive meetings over the coming year. For any of you who have attended any of our excellent industry association events — put on by groups like NAHAD, FPDA, NFPA, and others — you’ve probably run into one or more speakers from ITR Economics. (Our parent company, WTWH Media, has also run some online events featuring Alan Beaulieu of ITR, to talk about the economic challenges and outlook amidst the global COVID-19 pandemic.) Regardless, if you’ve heard anyone from ITR speak, you’re likely aware of what they say 2030 may mean for our economy. This year at NAHAD, Connor Lokar of ITR spoke about “How to manage in an uncertain economy,” and his presentation was excellent. But, as all his colleagues make sure to point out, we are headed for what his company believes is another “great depression” in the first half of the 2030s. A confluence of long-standing government spending decisions and demographic changes in the United States has been pointing to this conclusion for many years. That said, not all is lost … fortunes are often made during downturns, and properly prepared people and companies can certainly ride out a several-year period of difficult growth. Companies can focus on keeping the right mix of talent and build up their R&D spend during more profitable times. But something else Lokar said really resonated with me — it’s never too early to think about diversifying your family’s own work situation. Lokar encouraged each household to have multiple or diverse income streams. He said a worstcase scenario might be a husband and wife working at the same small family-run business. That sort of situation means that a downturn in that particular sector can be disastrous to the family’s financial stability. It’s often easier said than done, but it’s safer for two-income families to have vastly different jobs. For example, maybe one spouse would have a government job, while the other works in something else entirely, say healthcare or engineering. Certainly, achieving this isn’t possible for every family, but at least we have the better part of a decade to think about whether we need to make changes. In addition to engineering being somewhat recession-proof, Lokar mentioned the trades as a smart option moving forward. “When I think job security, I think plumbers, I think mechanical contractors, electricians. That’s what I think about the next three decades,” Lokar said. For those of us with kids, it might not be a bad idea to encourage them to consider learning a trade, either as a primary career, or something to fall back on. Otherwise, come 2030, they may be knocking on the door, and asking to move back in. FPW

Paul J. Heney

VP, Editorial Director

On Twitter @wtwh_paulheney



8 • 2021

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AUGUST 2021 C ontents |

vol 8 no 5





“Infinite” cylinder upgrades timber logistics The Hydraulic Infinite Linear Actuator offers a new way to generate mechanical linear motion.

Optimizing hydraulic fluids with the right additives The right lubricants can improve profitability, productivity, and sustainability.


Achieve a greener packaging line By integrating pneumatics technologies, consumer packaged goods companies can reduce their carbon — and equipment — footprint.


The evolution of hydraulic hose crimping From their humble hand-operated beginnings to IoT-enabled machines, hydraulic hose crimpers are a critical piece of equipment that any fluid power user should understand.


PackExpo returns with in-person event The event is slated for Las Vegas Convention Center September 27-29.

Rescheduled MinExpo to open in Vegas in September The event, which was postponed due to Covid-19 last year, is set for September 13-15 at the Las Vegas Convention Center. Utility Expo to open with higher attendance than previous years The renamed ICUEE event is slated for September 28-30 at the Kentucky Exposition Center in Louisville.



24 42 30 D E PA R T M E N T S

36 48 52 56





From The Field


Korane’s Outlook


Association Watch


Design Notes




Distributor Update


Energy Efficiency




Component Focus


Ad Index

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8 • 2021

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KORANE’S OUTLOOK Ken Korane • Contributing Editor

Back to the office, malware in hand Sooner or later, many companies will tell their remote workers to learn to live with Covid, and that it’s time to return to the office. Few are counting on a different kind of virus — ransomware — being part of the back-to-normal routine.

| Courtesy of Adobe Stock

As the pandemic forced employees to work from home, their laptops, smartphones and tablets have been in unsecured environments. The devices might have unpatched software, security controls deactivated or be infected with malware. Now, as people migrate back to their offices, networks and systems are at increased risk. Should ransomware breach your IT system, it locks all files using strong encryption and demands payment, typically in cryptocurrency, to restore operations. According to Backblaze, a global cloudstorage provider, there has been a staggering increase in ransomware incidents of late. Just this year, sophisticated criminal syndicates demanded $50 million from PC manufacturer Acer, shut down Colonial Pipeline, the nation’s largest fuel pipeline and extorted $11 million from meat-processor JBS. Other recent targets include hydraulic crane manufacturer Palfinger, Molson Coors, hundreds of supermarkets in Sweden and Ireland’s entire health system.

Attacks have become more frequent as amateur criminals get into the game by acquiring malicious code on the dark web for a fee. That makes almost every company, regardless of size and industry, a potential target. Numerous incidents go unreported as organizations fear damage to their reputations. Unfortunately, paying up only encourages more of the same. Ransoms now average around $200,000. And that doesn’t factor in the cost of production shutdowns and lost sales which can easily run into the millions. Worse, paying a ransom does not ensure that your data will be restored or you won’t be extorted again. Firms with ineffective security controls and out-of-date or unsophisticated IT systems are at the highest risk, as criminals concentrate on areas that provide the highest payback for the least effort. Often, a company’s employees are the weak link in letting viruses enter networks. Experts at the Cyber Readiness Institute say one simple solution to reduce the threat of ransomware: educate people to follow basic cyber hygiene practices that make it more difficult for miscreants to succeed. The non-profit has published a Ransomware Playbook to guide organizations of any size through the steps that will help prevent ransomware attacks. “Not every attack can be averted, but we’ve come to recognize that a lot of the behaviors individuals and organizations engage in, allow bad actors to take advantage of gaps in their cybersecurity. That’s why we focus on the aspects of human behavior that can help create a foundation for a strong culture of cybersecurity. It’s not about technology and it’s not



8 • 2021

complicated,” according to CRI. Among their recommendations, blocking access is key: • Train your staff on phishing prevention on their laptops, desktops, and mobile devices. Phishing uses fake emails and messages to trick people into clicking on links or attachments that introduce malware. It’s easy to spoof an email, so be wary of messages even from people you know. Likewise, visiting compromised websites, clicking on “malvertisements” and downloading content from social media sites are common avenues of infection. • Use strong unique passwords or passphrases. And use multifactor authentication to protect your accounts. • Make sure to install the latest security updates and patches from your software vendors. Use anti-malware software, but don’t rely on it to cover for lax practices and to catch all attacks. • Limit administrator accounts on your network. Then, prepare for the worst: • Ensure you have off-network back-ups that are kept up to date. Make frequent, comprehensive copies of all important files and isolate them from local and open networks. Offline back-ups, such as external drives or cloud storage, must be “air-gapped” and inaccessible from any potentially infected computer. • Test your back-ups regularly to confirm that they are usable and current. • Create an incident response plan with clear steps on what to do if compromised. The best defense against a ransomware attack is to avoid having one in the first place, noted CRI. Other than that, making sure your valuable data is backed up and unreachable by a ransomware infection will ensure minimal or no downtime and data loss if you ever suffer an attack. FPW



• • • • •

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ASSOCIATION WATCH Edited by Mary Gannon • Editor

IFPS honors 2021 Fluid Power Hall of Fame Inductees Now in its third year, the Fluid Power Hall of Fame, hosted by the International Fluid Power Society (IFPS), is pleased to announce seven new members and two posthumous individuals who have dedicated their careers and have made significant contributions to fluid power technology. This year’s group includes: Peter A.J. Achten, PhD has more than 40 individually titled patents in Europe, the United States, Japan, and through the World Intellectual Property Organisation (WIPO). He has also authored well over 200 survey reports, conference papers, magazine articles, books, and has presented invited speeches, workshops, and lectures around the world and in several languages. He is the recipient of the Robert E. Koski Medal from the American Society of Mechanical Engineers (ASME) and the Joseph Bramah Medal from the Mechatronics, Informatics and Control Group of the Institution of Mechanical Engineers. Timothy R. Bailey has been involved in fostering the development of all Australian fluid power organizations. Bailey has served as President of Western Australian Fluid Power Society Inc. for 12 years (1994-2006), President of International Fluid Power Society Australia Inc. for 8 years (2006-14), President of Fluid Power Society Australia Inc. for 2 years (2014-2016), and President of Fluid Power Society (WA) Inc. for 5 years (2014-2019). In leading these organizations, he concentrated on developing and promoting fluid power training and certification.   Jim Brizzolara has 56 years of dedicated service in fluid power. He co-founded HydraForce in 1985. Through his emphasis on quality and performance, including the formation of a Quality Support Administrative Team (QSAT), the company won industry awards and accolades including quality commendations from Bobcat, Caterpillar, Douglas Dynamics, Terex Genie, Clark Hurth, and Skyjack.   George Doig started in fluid power after WWII naval service. He completed his B.S.M.E. degree at Detroit Institute of Technology and worked several years for J.N. Fauver before he and three others founded Numatics in 1953. He rose to Senior Vice-President and Director of Sales/Marketing and participated in the rollout of Numatrol products. In 1966, he and L. Irwin Walle authored Practical Air Circuitry to address real, practical fluid power aspects. He was one of 30 founders of the IFPS and Chapter 1 in Detroit.   Craig M. Fox has focused on all aspects of excellence in fluid power education – including training design, teaching, and 12


8 • 2021

publishing educational materials — for most of his 41 fluid power years. He served as technical editor for the Lightning Reference Handbook published by Berendsen Fluid Power. He worked for Eaton a senior technical trainer and contributed to Eaton’s published Industrial Hydraulics Manual, an industry-recognized hydraulics textbook. Medhat Khalil, PhD, CFPAI is serving his 16th year as the Director of Professional Education and Research Development for the Applied Technology Center of the Milwaukee School of Engineering (MSOE). He won the 2012 Otto Maha Pioneer in Fluid Power Award and is the recognized authority on the design and construction of Universal Fluid Power Trainers, which he originally developed under a grant from the Center for Compact and Efficient Fluid Power (CCEFP) in 2009. He has authored five books on fluid power components, systems, fluids, and contamination controls as well as numerous periodical articles. Noah D. Manring, PhD, P.E., is a prominent educator-author who has served on the Mechanical and Aerospace Engineering Department faculty of the University of Missouri, teaching graduate and undergraduate courses in fluid power since 1997, becoming Dean of Engineering in 2020. He published 44 archival journal papers, 38 conference papers, and three books in fluid power. Manring holds 12 United States patents including his most recent 2019 “Check valve pump with two-phase flow control.” Post-humous awards were given to Richard J. (Dick) Fontecchio (1948- 2014) and Harley E. Bergren (1917 – 2021). Fontecchio cofounded HydraForce with Jim Brizzolara. With his leadership as VP of Sales and Marketing, HydraForce introduced over 15,000 standard and proprietary cartridge valves and their electrohydraulic controls. Bergren worked for Gates Rubber selling to agricultural equipment companies and later moved to Char-Lynn. In 1966, Bergren founded Power Systems in Minnesota, a fluid power distributor with expertise developing transmission systems. He retired in 1982 but held company stock until the 1998 sale of Power Systems. Visit for full bios on all 2021 recipients. FPW

FPDA, ISD and ESA prepare for Joint Annual Industry Summit

FPDA in partnership with the International Sealing Distribution Association and ESA, will welcome members and industry colleagues to Florida for this year’s Industry Summit. Registration for the three-day event, which will be held October 3-6, is now open. The event will be held at the Hilton Sandestin Beach Golf Resort & Spa in Miramar Beach, Fla. Keynote speakers will cover a diverse range of topics, including innovative marketing, economic trends, and business ethics. Networking opportunities at the Industry Summit include a charity fun run, golf tournament, bonfire on the beach, and receptions by the resort’s pools. In addition to board of directors meetings on day one, a welcome reception and Young Executive Event will be offered on Sunday, Oct. 3. The three organizations will each hold their Annual Meeting of Members Monday afternoon, followed by the Supplier Showcase & Reception that evening. Monday kicks off with general session, “What Big Brands Know” with Gerry O’Brion, followed by breakouts including a Young Executive Workshop, “Defining Your Purpose,” with Adam Livesay, and “IndustrySpeak – Warehouse Automation,” with John Norton, Chelsea Parker. Tuesday leads with a keynote presentation from Taylor St. Germain of ITR Economics, followed by more Industry Speak sessions of “IoT,” with Adam Livesay and a Distributor Panel, moderated by Bill Haley, FPDA, with panelists including Clyde Sharpe, ISD, ElastoProxy, Tom Nicholson, FPDA, GS Global Resources, and Chris Johnson, ESA, Johnson Hydraulic Sales. That afternoon, members can join the golf tournament at Baytowne Golf Course or choose to go on a fishing charter excursion. Tuesday closes with a beach bonfire. Finally, attendees can join the Beat the Sun Run in support of Lotus Learning & Arts Center Wednesday morning. Final sessions include “Rules vs. Principles,” with Andy Fastow, and post-Summit board meetings. Learn more and register at

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DESIGN NOTES Edited by Mary C. Gannon • Editor

Low-effort joysticks coupled with a new hydraulic control valve gives Bobcat’s R2-series E88 compact excavator improved metering, movement, and controllability, enabling a quick, smooth, and precise work group for ultimate operator control.

Compact excavator features advanced hydraulic controls The R2-series E88 compact excavator from Bobcat comes with several new advanced features to provide high power and lift capacity and extra productivity. The machine has a 14% increase in over-the-side lift capacity, as compared to the previous generation. The E88 comes equipped with dual-flange track rollers, integrated counterweight, extra machine weight and added track on ground. These new undercarriage improvements offer increased over-the-side lift capacity allowing operators to dig with greater confidence over the side of the machine. Bobcat compact (mini) excavators are designed with advanced hydraulics for faster digging. They’re also designed to dig while under load. And, if you can backfill quickly, you’ll save valuable time on the jobsite. Compared to other machines,



8 • 2021

Bobcat excavators put more power to the ground when engaging the tracks. Like other Bobcat compact excavators, the E88’s Tier 4 turbo charged Bobcat engine achieves emissions compliance without the use of a diesel particulate filter (DPF) or selective catalyst reduction (SCR). This means fewer components for easier maintenance, plus no work stoppage due to DPF regeneration. “The new model is designed for performance, ruggedness and operator convenience,” said Mike Wetzel, director of Product Management at Doosan Bobcat North America. “The R2-Series takes the key benefits from the prior generations with new improvements in lift performance, work group fine control and ride smoothness to push what is possible in a compact machine. The E88 is poised to help customers tackle the toughest jobs in a compact product.”

The E88’s narrow footprint ensures its leading lift capability. Along with the added confidence in over the-side-performance, the excellent slewing ability helps to push productivity higher. When you’re digging on a slope, slew force is the power you need to swing your excavator. It also determines how quickly you can move material back into your trench. Increased distance from sprocket to idler puts more track on the ground, which adds stability and helps to prevent a rocking sensation while lifting heavier loads. Improvements to the track design increase uptime and the overall life of the tracks as well. In addition, increased machine weight gives operators a rock-solid base for strong productivity, especially during the tough digging and heavy lifting tasks. The E88 is powered by a newly redesigned Bobcat engine that delivers efficiency and performance, plus simplified

routine maintenance. It also improves cold-weather operation and includes a variety of features that make maintenance and service more convenient. The new low-effort joysticks coupled with the new hydraulic control valve offers improved metering, movement, and controllability, enabling a quick, smooth, and precise work group for ultimate operator control. Bobcat’s exclusive control valve systems deliver consistent oil flow to all functions, which means smoother operation without sacrificing cycle times. Key new features include integrated lift eye, optional clamp diverter valve and an add-on counterweight option to propel lift capacity even higher. The optional clamp diverter valve provides enhanced hydraulic clamp functionality and improved ability to run other excavator attachments — without disconnecting the clamp. Additional hydraulic features include high-efficiency, torquelimiting piston pumps in the hydraulic system that match force to demand, continuously responding to loads and delivering more usable power. Bobcat highlights that its hydraulic horsepower is best in class, as their excavators deliver maximum hydraulic flow while working under pressure. In tests, Bobcat’s hydraulic flow outperformed other competitive brands by 40%. In addition, the E88 features an optional angle blade, important for fast backfilling and grading. This feature allows operators to angle the machine’s backfill blade 25° left or right to direct spoil from one side to the other — without forming windrows on both sides of the blade. A great range of downward positioning ability enables the perfect angle for stabilizing the machine on uneven surfaces or while trenching at an angle. The blade is also ideal for “dust panning” material into the bucket, providing extra versatility for jobsite cleanup. The E88 cab is designed to enhance operator efficiency, performance and comfort. The spacious interior houses an easyto-reach control pattern selector right underneath the seat, so operators can switch between ISO and standard controls without getting up or over-reaching. Optional add-ons include a waterproof, chemically hardened 7-inch touch display; the most advanced compact equipment in-cab display available. Via a wide and easy-to-use touch screen, operators can access their mobile devices via Bluetooth, connect with their dealer or customer easily through a quick contacts option and secure convenient touch operation without the inconvenience of glove removal.

Additional hydraulic features include highefficiency, torque-limiting piston pumps in the hydraulic system that match force to demand, continuously responding to loads and delivering more usable power even in rough terrains.


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The environmental demands placed on the hydraulic systems in large, heavy equipment can be extreme. Pressure, abrasive fluids, extreme temperatures, and dirt can all impact the reliability and performance of the seals used to protect their mechanics. Fortunately for manufacturers producing construction, agricultural, and mining machinery — among other heavy-duty industrial applications — Freudenberg Sealing Technologies’ proprietary 94 AU30000 polyurethane provides a solution — a fact that sealing distributors confirm through increasing sales of this material. Sealing solutions made from the AU30000 material are not only resistant to water and synthetic hydraulic fluids but can handle significant temperature and pressure fluctuations better 16


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8 • 2021

than any other existing polyurethane. They also offer very high extrusion resistance, allowing them to last longer under more challenging applications. Distributors operating within the Sealing Solutions Group — a group of five companies spread across seven locations in Canada that serve as one of the largest distributors of hydraulic seals, pneumatic seals, shaft seals, self-lubricating bearings, and other related components — offer a variety of AU30000 components to their customers and have reported a pattern of consistent performance and increased interest. “The AU30000 material really outclasses others in terms of friction and pressure resistance and overall mechanical properties,” said Robert Weber, a technical director for Sealing Solutions Group. “And with our machining capabilities, we can create custom parts that our customers require using AU30000 billet supply, resulting in

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reduce the number of needed parts in certain applications, resulting in easier installation and less downtime.

specialized seals and components that feature all the benefits of the material.” Seals and other components made from AU 30000’s bright blue, next-generation polyurethane have benchmark capabilities in areas like compression set, tear strength, hydrolysis, and extrusion resistance. They can be used to seal systems operating in hot and cold environments ranging from –40 to 248°F (–40° to 120°C). They are resistant to mineral oils, biodegradable hydraulic fluids, and water. They also offer a substantially longer service life,

saving customers downtime and maintenance costs, especially in fluid-based applications where hot water and steam are present. In addition to overall performance, seals made from AU 30000 can also reduce the number of needed parts in certain applications, resulting in easier installation and less downtime. “Any time you can reduce a two-piece configuration to a one-piece without losing any performance, it’s obviously a benefit,” said Jeff Fischer, a president within the Sealing

Solutions Group. “One example is that when using a rod seal made from AU 30000, you no longer need an anti-extrusion ring with it due to its excellent performance under pressure.” Freudenberg’s culture is driven through the principles of innovation, value, and customer service, among others. AU30000 addresses all of these areas, notes John Plut, Sales Director of Fluid Power for Freudenberg Sealing Technologies in the Americas. “Freudenberg Sealing Technologies is focused on its customers’ success,” Plut said. “By pairing our material knowledge with our extensive understanding of the Hydraulic Cylinder Market, we have been able to develop breakthrough materials like AU 30000.” FPW

Freudenberg Sealing Technologies

HOW ARE YOU ASSEMBLING PUSH-LOK HOSE AND FITTINGS? BARB-TECH III IS NOW AVAILABLE, a second tool with increased capacity has been added to our product line to handle up to 1” hose and fittings. WORKS WITH A VARIETY OF FITTINGS using easy to change Click-On mandrel system. Mandrel design services are available for your specific application. PORTABLE, take it to where the hose repair is, no additional tools needed, a convenient carrying case with extra storage is included. SAVES TIME, install fittings correctly the first time with an easy to load hose grip and up to 300 psi of fitting insertion force. REDUCES INJURIES by reducing required hand forces to a 1/3 of the typical fitting installation process of gripping the hose by hand.


TRAINING Ken Korane • Contributing Editor

Fluid power experts bridge the electrical skills gap Much has been said about the manufacturing skills gap, the disconnect between capabilities manufacturers expect from their workforce, and the knowledge and expertise that workers actually possess. However, another skills gap is emerging and is likely to impact virtually all industries — the electrical skills gap. With more emphasis than ever on digitalization, electrification and energy efficiency, most experts agree that we will need more employees adept in electrical and electronics technology to ensure economic growth and meet future sustainability goals. It is critical to develop and strengthen electrical skills in a range of workers. We recently asked Mathieu Plourde, Electric Power Technology Product Manager at Festo Didactic in Quebec, how fluid power experts can bridge the electrical skills gap. FPW: Does the electrical skills gap pertain to fluid power technicians or engineers? Plourde: It certainly does. Workers need to understand the full spectrum of possibilities

same basic concepts an electrical technician needs. Knowing basic electrical concepts is definitely required. Additional competencies regarding industrial controls, such as PLCs and sensors, helps the fluid power professional perform initial diagnostics and speed-up troubleshooting to minimize downtime in a production facility. Closing the skills gap is not meant to replace one type of worker with another, they all have their own expertise. But in today’s world, there is almost no industrial machinery without electrical components.

pertaining to the application they create or maintain. Fluid power experts are responsible for creating smarter applications by integrating new sensors, communication devices and smarter controls to create more reliable and energy efficient applications. In some applications, the technician or engineer must apply critical thinking to recognize when it might be more advantageous to integrate electrical actuators instead of fluid power actuators, in terms of energy consumption or complexity to integrate. Embracing and fine-tuning these skills enables them to work better in interdisciplinary teams and adapt to opportunities and complex situations ahead that will come with the general electrification and digitization of many industries.

FPW: Would the fluid power technician follow much the same learning path, or have different requirements? Plourde: Requirements would be different. Even for an industrial electrician, the learning path would be flexible and scalable to align to the specific needs of the institution, the individual and the industry, all which influence program requirements. For example, an industrial electrician in oil & gas will likely acquire more skill development around process automation to work in this area. The same goes for a fluid power

FPW: Would the skills needed for fluid power personnel be different from those required of the electrical technician? Plourde: The skills needed for fluid power workers are not as deep as they are for electrical technicians. However, FP professionals would certainly benefit from the

The Festo Learning Center is designed for production facilities and labs. It lets apprentices work with instructors on high-end Festo workstations that simulate actual work environments and go beyond classroom curriculum. | Courtesy of Festo AG & Co. KG



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Festo Didactic offers turnkey learning systems, e-learning and training courses. The cyber-physical platform CP Factory, for example, models stations of a real production plant and lets people learn subjects such as plant programming, networking, energy efficiency and data management. | Courtesy of Festo AG & Co. KG

technician. Certain topics will be customized to fit current fluid power technician training programs. However, the fluid power topics still need to get an “electrical revamp.” For example adding sensors and monitoring topics, to build smarter fluid power applications, enables remote monitoring and data collection to the cloud to evaluate necessary maintenance and ensure reliable operations. FPW: How does a technician acquire the needed skills? What kind of education or training is available? Plourde: The various skills needed can be acquired through different learning pathways. There is always the traditional educational institution program which is still relevant for teenagers wanting to develop a certain skill set. But nowadays, the same institutions offer micro programs tailored to individual learning needs. If you need knowledge in only specific new topics, you certainly can enroll in on-site classes with those institutions or training experts, which will get you what you need without going back to school for two to three years. The same can be done in collaboration with a company where multiple workers experience the same skills gap and align a program tailored exactly to the company’s needs. Technicians can also develop their competencies through resources available online. Festo LX is our online learning portal for high-tech industrial career training.




FPW: How does Festo train its own fluid power technicians so they have the requisite electrical knowledge? Plourde: Today’s fluid power technicians need electrical training and a basic understanding of connected factory systems. Festo integrates electrical, mechanical, pneumatic and fluid power concepts in its overall training approach. We cover this comprehensive approach to training in Festo’s Industry 4.0 Certification Program (FICP). We also use simulation software (FluidSIM) to upskill and ensure employees and students have access to the most up-to-date industry training. FPW: Will the traditional fluid power technician become obsolete? Plourde: The fluid power technician role will not become obsolete. Rather, the role will evolve and that is the important message for most technical jobs out there. Adapting to new technologies and applications in the digital era is of extreme importance for any type of technician, such as the fluid power technician. FPW


Festo |

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NAHAD continues to look ahead This year’s NAHAD Annual Conference came off splendidly at the Fairmont Scottsdale Princess resort in Arizona. Originally planned for earlier in the Spring, the Conference was moved back to June, because of continuing Covid-19 concerns. Then, a couple of months out, the organization also switched the location from San Diego to Scottsdale, due to concerns over restrictions that still might be in place in California.

The result was that the normal nice weather getaway was instead an amusing jaunt to daily 110°+ temperatures in the Valley of the Sun. But the staff and resort handled the near-record weather smoothly, moving some events indoors and setting up multiple water misters for outdoor functions. I caught up with NAHAD’s Executive Vice President, Molly Alton Mullins, to get a sense of where the organization has been — and where it’s headed. 20


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FPW: What are your feelings about this year’s Annual Conference, and what are the lessons learned for you and your staff? Mullins: I’m grateful; more than any other feeling, I think that is the best word I can use to describe it. I think we listened to our members. We polled them excessively to see what they wanted. Obviously, I wanted to do an event. This is what NAHAD is known for and what we do so well. If it wasn’t what the members felt comfortable with, then we weren’t going to go forward with it. Poll after poll said, “No, we want to come. We want to be there. We want to get together.” You certainly learn to be more flexible in the planning process. I don’t think I would have been as willing, maybe two years ago, to do this. After all we’ve lived through, now you think, “Yeah, we’re going to make it happen no matter how we can.” I think those are kind of the lessons we’ve learned from it. FPW: NAHAD Academy, which launched in 2019, seems to have been phenomenally successful. It was almost perfectly timed, as the pandemic was an ideal time to grow it by leaps and bounds. Can you talk about the genesis of it and where it stands? Mullins: I think we’ve really gotten lucky that those two worlds aligned at the time that they did. Previous to 2019, for the Hose Safety Institute and all of our training, members handed their employee this giant handbook, told them to read it, and then made them take a paper test. If you did that to me right now, I’d feel like, “I don’t want this job. I just don’t learn that way.” We took that information and turned it online to where people can take interactive courses, where someone’s talking to them. There’s pop-ups they can

| Courtesy of Adobe Stock

By Paul J. Heney • VP, Editorial Director

use. We all know how we learn and what we are visually attracted to nowadays. To be able to have all that implemented in 2019 so that when everyone was doing more training in 2020, it just gave us the opportunity to sell it more and to get more people involved. I can’t speak highly enough about Joanna Truitt ’s [Director of Training and the Hose Safety Institute] work behind all that because it’s not easy to take content like that and develop it into something that’s interesting, while still providing the detailed training that you need when you’re manufacturing hose. We launched in April of 2019 in Las Vegas at the NAHAD Annual Conference. At the end of 2019, we had 200 users. Now, we have 800 users. It’s been gangbusters; people are saying, “Yes, let’s get more seats involved.” You can sign up for a subscription as a company, or you can license the content and put it on your own website. There’s very NAHAD-specific training in there, but there’s also a ton of other training related to inventory management, sales and marketing, OSHA, and all those other sorts of things. FPW: Can you give some insight into the Hose Safety Institute? You’ve mentioned at this Conference that there are some new things coming. Mullins: NAHAD has always had a very interesting relationship with the enduser community. Obviously, we are a manufacturing distributor-based organization, but their customers are the end users. What a lot of the Standards Committee members have said is, “Let’s engage them more. Let’s actually give them access to our educational content, so they understand why they want to work with a Hose Safety Institute member.” That’s always been my goal — to have an end user go to one of my distributors and say, “Hey, are you a member of HSI, so I can make sure that you’re doing things appropriately?” To be able to educate them is something that we’ve never really done before. I’m super excited to see how that goes. We’ll be developing courses directly for them, so that end users — free of charge — can log on the system and learn what they need to be

asking questions for and what they really need to be looking for. That’s a lot of what Joanna and her team are working on for this year. FPW: We heard a great presentation by Ian Heller yesterday. Some of what he talked about was pretty scary stuff, though. He said that distributors must be laser-focused on marketing their value-added services, due to encroaching competition from Amazon and the like. What is NAHAD doing for its members to help train them to deal with what’s coming in the next 5 or 10 years? Mullins: Our focus is a lot on providing them the education to know what’s ahead — as best as any of us can predict. To have people like Ian, who also does webinars for NAHAD members, to help them kind of understand forecasting and understand what supply chain challenges are out there and really understand what other types of different disruptors they have in front of them. It’s really for us to get as much information to them as possible. Then it’s up to them to prove what their value is going to be. Distributors do work that nobody else is going to do for a customer. There is inherent value in that — that you can’t replace. It’s showing them how to better educate and market that message. I think that is something that we try to do at NAHAD. FPW: Are there any other issues that you hear consistently from your members, things that keep them up at night? What are distributors most worried about today? Mullins: It really boils down to two key elements with them. It is supply chain and it is personnel. None of us, our own company included, can hire and retain as many people for the work that we all have going on right now. How do you keep and retain the employees that you have and keep them from burning out? How are you attractive enough to that next employee to bring them in? I heard the other day that McDonald’s is offering $50 to simply interview, not even to take the job, simply to get people to come in and interview. This is everywhere. When you’re looking at manufacturing and warehouses, what can you

Molly Alton Mullins, NAHAD Executive Vice President incentivize to encourage that employee to really take that job and stay there? Then supply chain. Connor Lokar did the opening talk, the economic presentation. He spoke a lot about supply chain. It’s going to be a year. I mean, that is what every economic prediction says now. Demand won’t normalize until June of next year. We just had this influx of demand with such a limited supply, given everything that the pandemic produced. That’s a lot of what they’re trying to balance, as well as — how do you get your customers to understand that and know that it’s not going to be overnight, and this isn’t going to be fixed. How do you mitigate and work through it? FPW: You just announced the May 14-18, 2022 dates for the Annual Conference in Miami next year. What can attendees expect in 2022? Mullins: People are super excited about Miami. The largest Convention they had ever held was in Miami in 2015. They love the location. We’re right on the beach. We have deliberately, for this year’s program, built in downtime. We want to let people do what they want to do. Again, it’s listening to our customers tell us what they want instead of telling them, “Go to an education session. Go do this.” Right? Because they want to connect. They want to conduct their business meetings. They want to meet one-on-one and have sales meetings, those sorts of things. We will continue to build that into our program. I do think that this NAHAD is going to bust at the seams because of the pent-up demand of people who couldn’t be here, including all my international members. I’m missing at least 20-25% of attendees from Europe, Asia, Canada, who couldn’t travel. All of them have said, “We will see you next year. We will see you next year.” I expect it to be one heck of a party for everybody. FPW

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ENERGY EFFICIENCY Ron Marshall • Contributing Editor

Compressed air fail: Hot and cold An electronics parts manufacturer had a maddening water problem. Every day around noon, its air system pipes started emitting free water at their most important end uses. This water came mixed with compressor lubricant and the dust ingested by the compressor intake. With the addition of pipe rust and scale — which formed due to water corroding the inside of the steel pipes — this made a real mess and was causing product quality problems. Examination of the drains

This site had both wet and dry receivers, and adequate filtering, but was still experiencing water contamination within the plant.

on the dry side of the refrigerated air dryer revealed no free water during these times, but water still mysteriously formed inside the pipes in the plant. This problem continued off and on until the plant manager called in a compressed air auditor, who hooked up measurement instruments to the system. In addition to monitoring pressure and power, compressed air dew point was also checked over a period of a week. These readings revealed a problem happening during the hottest time of the day, when the compressors were heavily loaded. This, when coupled with the environmental conditions in various areas of the plant, allowed water to form. The plant was located in an area of the world where daytime temperatures were elevated and ambient humidity was very high. The measurement instruments showed that the air compressors discharge temperatures were in the 120° F range during mid-day because the compressor room was located outside in near 100° heat. The air dryer was not sized for this abnormal temperature and struggled to keep up. Dryer discharge dew points were peaking in the 80° F range during these times — not high enough to cause free water to form in the dry receiver and filters of the outdoor equipment. Yet, when the air entered the plant, with ambient temperatures in the 72° range due to air conditioning, water condensed out of the compressed air, causing contamination. The problem was an undersized dryer due to excessive temperatures. A new dryer was sized based on higher worst case conditions, solving the water issue. FPW



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It’s a big year for us at Motion. We’re turning 75! Our story begins in 1946, the year following the end of World War II, when two friends, a U.S. Marine Corps veteran and a U.S. Navy veteran, bought the industrial parts supply business Owen-Richards and opened the first location in Birmingham, Alabama. Though the Company started as Owen-Richards in 1946, William Spencer and Caldwell Marks renamed the Company “Motion Industries” in 1972. The name conveyed the purpose of keeping machinery – and industry – in motion.



“Infinite” Cylinder upgrades

timber logistics

The Hydraulic Infinite Linear Actuator offers a new way to generate mechanical linear motion.

Magnus Landberg, Landberg Solutions AB • Magnus Sethson, Linköping University • Linköping, Sweden



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HILA actuators installed on logging trucks and trailers let drivers automatically adjust spacing of the upright support stakes. That can improve vehicle aerodynamics, accommodate varying log sizes and eliminate dangerous manual tasks. | courtesy of Adobe Stock

In the forestry industry, robust and power-dense hydraulics have long played an important role in successful and costeffective operations. Today, there is also a trend towards larger timber transport vehicles that consume less energy. One way engineers can keep up with these demands is by taking advantage of a new sort of hydraulic linear actuator technology, embodied in the Hydraulic Infinite Linear Actuator (HILA). It can help improve vehicle aerodynamics, accommodate varying load sizes and weights to raise productivity, and automate dangerous manual tasks to enhance safety. It is also suited for agricultural operations to ensure high-yield and sustainable farming. Here’s a closer look at HILA fundamentals and applications.

HILA basics

The HILA generates long actuator strokes from a short cylinder body. It is based on well-known hydraulic clamping technology, where the piston and rod can be coupled and uncoupled by means of a clamping element. The HILA actually combines two short-stroke cylinders with two coordinated, engaging and disengaging clamping mechanisms into one actuator with a long stroke length. The motion of each single short-stroke piston, linked together by the internal clamping mechanisms, drives the piston rod. One piston at a time connects to the rod, shifting the load from one cylinder to the other and alternatingly moves the rod in a kind of “handover-hand” rope climbing motion. Simple logic valves control the flow. The clamping mechanism, essentially a hydraulically activated membrane, maintains friction and load-holding capacity. It is pressurized and engaged by a separate port through the

piston using a dedicated 3/2 valve. Here, minimal flow is needed to pressurize the small membrane volume, so a small and fast-operating valve can be used. Piston movement and clamping actions are independently controlled by a timing procedure. (Readers can view the actuation process at www. Because piston areas in the cylinders are symmetrical, there is marginal variation of oil volume during operation, compared to conventional hydraulic actuators. Another advantage is that the system needs only a fraction of the hydraulic oil versus an ordinary long-stroke hydraulic cylinder and, thus, requires a much smaller oil reservoir. One challenge is to generate linear motion with a low pulsation level. In many applications, however, smaller pulsations are acceptable. The technology is best suited for applications with relatively slow dynamics and where movements are largely kinematic and well-understood.

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In contrast, traditional long-stroke cylinders face several hurdles. Buckling is probably the main problem. It can be overcome in some applications using a pulling cylinder. Hydraulic stiffness and hydraulic capacitance can also have an unfavorable effect on dynamic behavior and controllability. Longer hydraulic cylinders usually face difficulties at high pressure, as it reduces the system natural frequency. Thus, advantages normally associated with hydraulics — compactness and high power density — diminish with increasing stroke length. The Hydraulic Infinite Linear Actuator solves these problems. HILA provides long strokes at high system pressure, with a higher stiffness compared to conventional hydraulic cylinders. Each HILA cylinder has a much shorter body, so a sufficiently high natural frequency can be achieved at high system pressures. And bulk modulus increases slightly with increasing pressure. These are favorable factors in terms of actuator control design. The compact and lightweight system, built with robust and cost-effective standard components, is well suited for tough and demanding environments, especially in mobile applications, where there presently are no alternative solutions. Strokes as long as 7 to 8 m (23 to 26 ft) are possible, depending on the piston rod diameter, for pulling loads in horizontal applications. Even longer strokes can be implemented in vertical applications, such as in elevators. As the HILA technology needs small cylinders and low oil volumes, it is possible to design compact and long stroke electrohydraulic actuators (EHA). Symmetrical piston areas simplify the design. HILA technology also lets several active actuators to be positioned and locked on the same piston rod, which can be advantageous in certain applications. This means that several processes can be performed in parallel instead of serially, without the need for a dedicated actuator for each element. Here’s a look at two such applications. One involves timber vehicle aerodynamics and logistics; the other shows how HILAs can flexibly and optimally position row units on agricultural planters, to secure productive and sustainable farming. More-efficient timber trucks

There is a great need in forestry transport to reduce fuel consumption and limit variable costs and carbon dioxide emissions. One solution is to develop larger vehicles that carry greater loads and reduce transport cost per mile. There are likewise opportunities to improve vehicle aerodynamics, as air and rolling resistance are two of the most important factors that hurt fuel economy. Truck manufacturers put a lot of effort into reducing

The HILA combines two short-stroke cylinders with two coordinated clamping mechanisms, one in each cylinder. Simple logic valves control the motion. The compact and lightweight system permits strokes of more than 25 ft. Or several actuator bodies can move along a stationary rod, for use in timber transport and agricultural seeding applications. | courtesy of Gustav Näslund, GN Tech

air resistance through better aerodynamic design of the cab and chassis. For the trailers, no similar development has taken place. Complicating matters, a timber trailer is like two completely different vehicles, loaded and unloaded. When unloaded, several points experience strong turbulence, specifically around the vertical stakes that support the logs; and around the horizontal banks — the structural cross-members that hold the stakes in place and on which the logs sit. Simulation studies show that the biggest aerodynamic problems for unloaded timber trucks are turbulence under the trailers, and air resistance due to stakes and banks that stand upright in the air stream. Bundling stakes and banks together at one point would significantly reduce air resistance, depending on vehicle speed. The trend is toward timber vehicles that drive longer distances at higher average speeds, due to fewer and larger sawmills and pulp mills. As air resistance increases with the square of the speed, the need for consolidated banks and stakes is even more important for fuel economy. The same holds for aerodynamic resistance and turbulence that banks and stakes create on unloaded timber train carriages. While unloaded timber trucks drive at maximum speeds of around 100 km/ hr (60 mph) in the U.S. and Canada, freight trains travel at even higher speeds. Studies show that covering unloaded coal wagons can reduce air resistance by more than 40%. HILA advantages

HILA systems can address these issues. With HILA technology, banks and stakes on timber vehicles can be individually positioned, automatically, with high locking force. The system can also significantly increase vehicle flexibility and open up more combinations that facilitate cost-effective and environmentally friendly logistics for both timber and complementary goods flow. Key functions on towing vehicles and timber trailers include: The vertical stakes and horizontal banks on unloaded timber trucks cause significant aerodynamic drag when traveling at highway speeds. Bundling them together at one point reduces air resistance and can cut vehicle fuel consumption by around 5%. | courtesy of Gustav Näslund, GN Tech



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Bundling of banks and stakes for better aerodynamics. Consolidating banks and stakes at one point on the trailer or behind the cab will reduce air resistance and, thus, cut fuel consumption and carbon dioxide emissions by about 5%, according to a study of forest vehicles by C. Löfroth and O. Gelin. Use on timber trains can produce similar benefits. Enable different bank and stakes combinations. Today’s timber transports are also characterized by a great variation in timber length, which can change with each trip. Thus, there is a need to combine different-length stacks, from 2.6 to 6 m (8.5 to 19.7 ft) on the same vehicle. The HILA actuator lets operators switch bank combinations to accommodate different timber lengths, based on the number of stacks and the length of wood on each stack.

Timber trailers can have up to eight banks. With HILA actuator technology, adjustment between 2, 3 and 4-stack combinations can be done smoothly via an in-cab display. This eliminates the difficult and hazardous manual work needed to push the heavy banks and stakes between various positions, significantly improving driver safety and saving considerable time. •

Bank shifting. In addition to lowering air resistance and fuel consumption, it is also

• •

important to minimize the empty weight of vehicles. Most timber trucks that load with their own crane have a bank shifter, a hydraulic cylinder that moves the banks forward for loading. Because the crane has a limited range, one stack is loaded and then pushed back to load the next. The typical bank shifter is a 4 m (13.1 ft) long hydraulic cylinder that weighs 400 kg (880 lb) and requires a large hydraulic tank. A compact HILA system at about half the weight (200 kg) with a smaller hydraulic tank can readily perform the same task and generate actuator forces up to 170 kN (38,000 lbf). Adjustable center of gravity. Center of gravity balancing of stacks is important to get the proper weight distribution and avoid overloading any axle group. Gap-filling. Minimizing gaps between stacks reduces air resistance of a loaded vehicle and improves the torsional rigidity of the trailer. Easier inspection. HILA can quickly disassemble stacks and facilitate inspection. Allow for complementary cargo. With HILA technology, towing vehicles, trailers and trains can easily be repurposed to carry 20 to 40-ft shipping containers. This creates opportunities for valuable complementary freight flow and large savings with respect to time, costs and climate impact, especially on long transport routes.

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HILAs can reposition banks and stakes to accommodate various log lengths, and consolidate them to reduce air resistance or allow complementary cargo such as shipping containers. Operators make the adjustments via an in-cab display.

Tools Sizing & specification ▪ Online calculations & product selection

▪ One-on-one

application assistance

Resources Online & downloadable ▪ ACE CAD database ▪ ACETips video tutorials ▪ Technical blog & case studies


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Visit us at booth # 8124



Precision seed drills

A key to productive and sustainable farming is planting seeds at an optimal distance from each other. However most present seeders have a fixed row distance and, thus, low adaptability for different crops or soil conditions. Even when possible, changing row spacing is time consuming and expensive, as it can take two working days to manually adjust row spacing on a precision seed drill. Further, the machine is out of production, especially Most farm seeders are built with fixed row spacing, which critical in the spring planting season. limits adaptability for different crops or soil conditions. One possible solution for variable row spacing is Mounting numerous seed drills on a HILA permits fast and to densely pack seeding units on the machine arms variable row spacing on machines for precision sowing. and only activate certain ones to obtain the proper | courtesy of Per Frankelius, Linköping University row spacing. But driving around with excessive dead weight is impractical. HILA technology enables numerous seeding the tractor cab, and fine-tune the inter-row spacing depending on elements to be positioned along a row, with high locking force. Operators the types of crops and soils. The HILA concept allows for countless can implement fast, efficient, and variable row spacing on machines for configurations for different seeds, and spacing can be independently precision sowing, inter-row cultivation and crop harvesting. This means adjusted with high precision. that the same machine can be used for different crops and meet farmers’ Operators can also reconfigure spacing on-the-fly if one unit fails, demands for common multi-purpose equipment. so planting can continue without having to wait for a service technician. A HILA can quickly shift the position of drill units as needed. This contributes to higher productivity. Similarly, for easier servicing, it is Operators can vary the distance between drill units from a display in possible to open large spaces around a specific row unit with the push of a button. While it is beyond the scope of this article, HILA technology can also let operators vary the arm width of seed drills and planters, and fold the arms for transport on roads. It offers the possibility of longer arms and a simpler and faster folding mechanism, with a more optimal center-of-gravity, more stable vehicle dynamics and higher travel speeds. A demonstrator has been successfully tested and meets the initial functional requirements. The next step will be to build a full scale seed drill. As part of Sweden’s Agtech 2030 innovation program, the project involved collaboration among Saab Ventures, Sweden’s Rural Economy and Agricultural Societies, GN Tech, and Landberg Solutions. The hydraulic research division (FLUMES) at Linköping University has been instrumental in this work. FPW

Landberg Solutions AB | A HILA can quickly shift the position of a seed-drill unit, and hold it in place with high locking force. | courtesy of Per Frankelius, Linköping University



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When the Pressure Is on,

Quality Makes the Difference

Hydraulic Valves

Mobile and Industrial Valves • Control Valves • Selector Valves • Lock Valves • In-line Valves • Restrictor • Relief • Check

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1/25/2021 3:51:24 PM


Achieve a greener

packaging line

By integrating pneumatics technologies, consumer packaged goods companies can reduce their carbon — and equipment — footprint.


Mark Densley Director Business Development Factory Automation Emerson



Pneumatics 8-21_FPW_Vs3.indd 30

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8/16/21 12:03 PM


Customer demand, as well as a sense of environmental responsibility, is driving consumer packaged goods (CPG) companies to drastically reduce their carbon footprint. While many companies seek ways to make their packaging material more sustainable, they can also save a significant amount of energy by monitoring pneumatic components in their packaging lines.

Cost-effective and compact, pneumatics has been a steadfast technology in the consumer products market for years, playing a vital role in a wide range of packaging systems. However, they are now goto components for even more reasons: These proven solutions have valuable capabilities as well as comprehensive, actionable data that can optimize energy use, improve overall equipment efficiency and maximize performance. Here are two ways in which CPG companies can integrate pneumatics into packaging lines to reduce their carbon footprint and deliver a more compact, greener packaging line. Compressed air

Compressed air is used to help operate equipment and power processes throughout packaging lines, including bottle production. While its prevalence can mean a high potential for energy loss, the right tools can turn it into a valuable opportunity for energy savings. Not long ago, there was no reliable way to evaluate compressed air consumption. The digital transformation of pneumatics has changed that. Today’s smart pneumatic devices provide a more complete picture of pneumatic system performance as well as actionable insights that give companies the ability to better understand and effectively control the energy use of their packaging lines. Smart sensors, combined with an edge computing device, can continuously monitor system airflow and capture real-time flow, pressure and actuator speed. When properly analyzed, this data can help detect leaks and optimize compressed airflow, as seen in Figure 1. Using the edge analytics, operators can see the relationship between air pressure, flow and the speed of the actuator more clearly. By better understanding the true nature of this relationship, operators can determine the optimal consumption point of compressed air for their packaging processes.

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Figure 1: Emerson’s AVENTICS Series AF2 Series air flow sensor continuously monitors air consumption in compressed air systems to help identify leaks in real time and optimize consumption. | courtesy of Emerson

If the analyzed incoming pressure is higher than a process requires, and more compressed air is being used than needed, operators can reduce the pressure and modulate airflow while maintaining the same cylinder cycle time. By optimizing the amount of compressed air to meet operational requirements without affecting production, companies can minimize energy use. In addition to optimizing compressed air use, software monitoring can also help operators detect leaks in near-real time. Once it detects a leak, the monitoring system sends an alert to maintenance personnel, who can then investigate the equipment in question. In this way, operators can address compressed air leaks much sooner, preventing compressed air loss and reducing emissions, Figure 2. Depending on the size and nature of the machinery being monitored, companies can typically save 10-20% in compressed air energy costs and see a carbon footprint reduction of up to 10% through early leak detection and optimized air consumption. System monitoring can help reduce 32


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downtime and improve overall equipment efficiency (OEE), too. Companies no longer need to plan downtime and have technicians test each machine for leaks, and leaks are sealed before they can cause fluctuations in system pressure. Leak-related fluctuations can make machines cycle more than needed, and this extra work wastes energy, prematurely wears equipment and components and increases maintenance. PET bottle production

The polyethylene terephthalate (PET) bottle is the most widely used bottling product in the world. It is so popular, about 3,500 stretch blow molding (SBM) systems are built and deployed annually to meet demand. The latest systems combine the SBM process with the bottling process in one continuous production flow. This combination production system obviously makes lines more compact and reduces a bottler’s carbon footprint by eliminating the shipping step that occurred between bottle production and filling. Pneumatic technology is a key part of their construction. Pneumatics powers several key areas of SBM machines. Pneumatic air preparation systems improve efficiency and offer better

control of the low- and high-pressure air that preform actuators and stretch blow bottle expansion steps use. And compact, highperformance blowing blocks provide bottle volume growth control through pre-blow, blow, recycling and exhaust functions. Some suppliers have advanced SBM pneumatic performance, and sustainability, even further. For example, Emerson offers a proportional control valve developed for the pre-blow expansion step in PET production that replaces an on/off high-pressure flow and, quite honestly, revolutionizes this bottle production step. Where the previous on/ off high-pressure flow set a uniform flow rate throughout the blow process, the new control modulates the flow to fine-tune each bottle’s expansion within the mold, as indicated in Figure 3. This advanced proportional valve technology combines a specially designed proportional valve, control electronics, and software, which can either store the blowing sequence setpoints in the valve or respond to control directions from the stretch blow molding (SBM) programmable logic controller (PLC) that directs the blowing process. The resulting bottle grow is intelligently modulated, giving end users the ability to perfect how the heated bottle expands within the mold. The system can also capture feedback results for the quality of each blow, providing critical data needed by bottle manufacturers to perfect the process and minimize the number of rejected, wasted bottles. It also provides condition monitoring data to support routine and preventive maintenance programs. Proportional technology for PET blowing moves pneumatics to a whole new level of sustainability for this process. It offers the potential to reduce material consumption with the capability to fine-tune bottle wall and shape formation, to create thinner, more lightweight containers. It also saves energy by potentially reducing blow air pressure required for high-quality bottle formation and by reducing the heating temperature in the pre-blow oven. In addition to its energy saving benefits, proportional technology for PET blowing also enables the high throughput production of more complex bottle shapes, which is a


critical goal for a bottler’s marketing purposes. It also increases manufacturing flexibility, since the process can be easily changed via software/PLC formula specific to each blowing station on the machine and fine-tuned for further improvement without stopping production. Conclusion

Consumer packaged goods companies have long counted on pneumatics as an effective, reliable machine technology to package items from soda bottles and cereal boxes to single-serve snack pouches and pharmaceutical blister packs. And the latest advances in pneumatics, including the digital transformation of the packaging line, promise even greater benefits. While the right technology will power greener, more compact packaging lines, it’s important that CPG companies work with an automation expert who understands smart pneumatics and the distinct characteristics of fluid power applications to achieve their most ambitious sustainability and performance goals. By using a range of pneumatic technologies, including smart pneumatics, companies have the potential to significantly reduce their carbon footprint — while considerably improving OEE.

Figure 2: A local dashboard for pneumatic applications demonstrates how the system visualizes data, detects issues such as leaks and provides end users with valuable insights for early intervention. | courtesy of Emerson


Emerson |

Figure 3: In PET bottle production, the integration of a proportional control valve in the pre-blow expansion step provides a greater control of each machine station than on/off high-pressure flow models can. 34


8 • 2021



The evolution

of hydraulic hose crimping



8 • 2021

From their humble hand-operated beginnings to IoT-enabled machines, hydraulic hose crimpers are a critical piece of equipment that any fluid power user should understand. Josh Cosford, Contributing Editor You’d be hard-pressed to find anyone in this hydraulic industry who has never made a hydraulic hose assembly. Hydraulic technicians make their livings fabricating plumbing of various configurations. Still, even designers and engineers likely got their hands dirty in school as part of an intro class on the subject. More often than not, fluid power professionals cut their teeth in the local hose shop before moving through the ranks of a distributor or manufacturer. Nevertheless, many of you now reading this are familiar with the techniques used to crimp a hydraulic hose. As you’d expect, hose crimping equipment originated with humble beginnings. Any machine capable of exerting radial force upon the outside diameter of a hose-end ferrule would do the trick. Early on in their designs, engineers took advantage of the cone and seat arrangement for the crimping dies, a system still most popular today. The collet acts as a seat, and when it pushes against the cone shape of the dies, the dies are forced inward. So long as you could push either the dies or collets to achieve the desired inward force vector, the conical shape offers a mechanical advantage to aid in the compression of the hose end ferrule. The first hose crimping technology used good old-fashioned human power to achieve the desired result. Early swaging presses operated by turning a large T-handle, rotating a machine screw through a fixed head, forcing the end against the two-piece die set. In the case of these portable hand swagers, the dies move downward against the fixed collet, and as the dies move downward, they also compress inward. The technician must hold the hose end carefully with one hand as they spin the handle with the opposite hand. Once the dies grasp the fitting firmly enough, the technician then uses both hands to muscle the crimper until it bottoms out. It’s essential to use only the matching dies and hose ends specific to the application.

8 • 2021



Hand-swagers came first




Illustration shows how the collet of a hose crimper acts as a seat, and when it pushes against the cone shape of the dies, the dies are forced inward.

These portable hand-operated units don’t offer the same automatic crimp diameter technology as new systems employing micrometers. You simply clamp the unit until the two-piece dies bottom out and hope you achieve your crimp spec. Measuring the crimp still offers the technician confirmation that the crimp resides within specification, but they need to count on their experience with the device to produce consistently accurate results. I should also mention, many technicians still use portable hand-swaging machines today. Hydraulics add speed and power

Something is satisfying about a hydraulically powered hose crimping machine. An allelectric machine just doesn’t feel right, like a meatless burger or a Mazda Miata with an automatic transmission. The addition of hydraulic power density to the crimping machine offered the technician a quicker and more powerful method of crimping hose ends. The collet on the hydraulic crimper is essentially an annular hydraulic cylinder. In some cases, two cylinders push on such an annular ring. The force created from the cylinders pushes either the collets or dies, forcing the latter to close upon the hose end with high force. The primary difficulty with early crimping machines was their lack of versatility. The dies used were specific to the hose end, encouraging the technician or hose shop to use only products sourced from the same manufacturer. If a shop wished to use various hoses and ends, a method to vary the crimp diameter had to offer variability in the crimp OD while still offering accuracy down to the thousandths of an inch.

Portable hand crimpers, such as this design from Finn-Power, use manual hand power to turn a T-handle, rotating a machine screw through a fixed head, forcing the end against the two-piece die set. 38


8 • 2021

Rather than limit the technician to fixed diameter dies, instead offering dies capable of a range of internal diameters brought in that variability to allow multiple types and sizes of assemblies. Instead of an exact diameter of, say, 0.733 in., the dies now offer a range from 0.700-0.788 in. for example. What could previously only crimp a ½ in. hose end may now crimp 1- and 2-wire hose from 3/8 to ½ in. Dies designed for variable diameter applications present the challenge of accuracy, of course. The dies can only bottom out on their smallest setting, which may not always be helpful for any hose or fitting the shop offers. Crimp machine designers had to engineer a method to stop the crimping procedure at the desired size accurately. No technician is skilled enough to stop the hydraulic pump by feel with 0.002 in. accuracy or better. Accurate and repeatable

Installing an adjustable limit switch offered the most accurate and repeatable solution to the variable die set. An adjustable micrometer attached to the limit switch allows the technician to set the depth of the limit switch to within a thousandth of an inch or less. When the crimp actuator contacts the limit switch, the pump stops automatically. So long as the micrometer has been calibrated, the crimp diameter is both accurate and precise for every single operation. Hydraulic crimpers using the micrometer were the standard for decades, offering precise control to make hose assembly quick and straightforward. Much of the advancement, until recently, has been improvements to the practicality of the machine. Dual-stage hydraulic pumps provided the technician with rapid die travel until the clamping pressure was met, where the stages switched to the smaller, highpressure pump for maximum force. Convenient die storage systems to offer rapid and precise tooling changes also sped up the pace for busy hose shops changing between sizes. A die-set loader offered the technician ease of pulling dies from their holder where they’re inserted into the crimper before being clamped in place. The tidy die storage and replacement systems so widespread today beat the old habit of

Industry 4.0 is making its way into hydraulic crimping technology. Here, Gates’ GC20 with Gates Cortex Intelligence features intuitive touchscreen controls, on-board training, integrated eCrimp settings and remote support. These technological advances safeguard crimper operations, and take the guesswork out of crimping operations.

sifting through drawers or bins where every die of every size mingled with no organization. Electronic control

Just as the rest of the industry moved towards electronic control, so too did the hose crimping machine. Some technicians found the

traditional dial-micrometer hard to read and adjust, and often found itself out of calibration. Linear position sensors replaced the limit switches, and then the adjustment option went digital. A small LCD screen shows the crimp setting, which increased accuracy and reduced the chance for error. The precision of

the linear transducer all but guarantees perfect, repeatable crimps. Some hydraulic hose assembly equipment manufacturers have produced semi-automated hose assembly stations. One such machine requires only that the operator load the parts into the machine. The operator loads the stems

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Integrated die storage is included in many modern crimpers, allowing for quicker and more accurate hose assembly production. |

and ferrules separately, two at a time, and then inserts the hose ends into the machine. The operator starts the sequence that inserts the stems into the pre-cut hose ends along with the ferrules. The operator unclamps the hose assembly, and if it’s long enough, simultaneously inserts each end into the automatic crimper. A moment later, the technician pulls out a complete hose assembly. If the hose length isn’t long enough to span the gap and into the two openings, the ends are done individually but in parallel. The insertion and crimping functions are completed while the technician works on the opposing operation. Capable of two hundred complete hose assemblies per hour, this machine quickly offers a return on its investment. Crimpers get smart

The industrial world continues to find new and creative ways to utilize Industry 4.0 concepts, and hose crimping technology is no different. Busy hose shops require speed and versatility, leaving little time for thumbing through catalogs looking for crimp specs. Many top crimp manufacturers offer high-end machines with touch screen HMIs employing wireless links to the manufacturer database. This system might not be impressive for the technician who has memorized the crimp specs for their standard 100R1 or 100R2 assemblies. But when they’re asked to crimp various assemblies of stainless wrapped thermoplastic hose, they’ll be elated to know the required die information pulls up on the touchscreen. A quick selection of hose, dash size and stem results in readily available crimp specs populated right into the crimper settings. Just like the fluid power industry at large, crimping technology will continue to advance. Expect to see augmented reality identify the hose and fittings visually, such as with QR codes, then automatically populate crimp specifications. Expect hydraulic hose crimping technology to become more versatile, more productive and more easily maintained. FPW

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8 • 2021

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8/16/21 1/26/2112:03 6:52PM AM



Optimizing hydraulic fluids with the right additives

Blayne McKenzie, Strategic Technology Manager, Industrial Products, The Lubrizol Corp.



Mobile Hydraulics 8-21_FPW_Vs3.indd 42

8 • 2021

8/16/21 12:04 PM

The right lubricants can improve profitability, productivity and sustainability. Procurement decisions in almost any market you can imagine are driven primarily by one or more of the following three factors: profitability, productivity and sustainability. In the rapidly evolving world of hydraulic equipment, hardware is changing quickly to meet demands for more throughput on both mobile and stationary equipment. This requires each system component to operate under ever more challenging circumstances. But it is not just the hardware that is changing — hydraulic lubricants must also change in lockstep with the hardware. After all, the evolving equipment is operating at higher operational speeds and pressures, increasing use of electronic control, greater precision and accuracy, and more compact systems that demand smaller lubricant sump capacity. In light of the rapidly changing equipment requirements, one thing remains constant: Facilities cannot afford the effects on profitability of unplanned downtime. To prevent that from happening, lubricants also must not fail. Lubrizol’s research has focused on creating a total hydraulic solution by combining industry-known, durable additive chemistry with shear-stable, energyefficient polymers. This combination of chemistries improves profitability through reduced fuel and energy costs; productivity by keeping equipment in working order more consistently; and sustainability by reducing energy consumption and carbon dioxide emissions—all while maximizing lubricant durability.

Figure 1. As a result of its distinct molecular structure, Lucant lowers the number of parasitic losses that occur when fluid flows around bends, twists and turns, or through valves, filters and other nonlinear hardware flow paths. This image illustrates a secondary flow field (denoted by the arrows) as a fluid navigates a 90° bend in a pipe.

8 • 2021





Passing the test

Figure 2. Adding a specially designed performance polymer called Lucant helped maintain durability in the Eaton 35VQ vane pump test. The end-of-test weight loss measurement clearly stays within the published test limit.

Figure 3. The 200-hour KRL bearing shear test data proves the improved shear performance of Lubrizol’s total hydraulic solution, as it stayed well below the 15% viscosity loss threshold three times longer than a conventional multigrade hydraulic lubricant.

No lubricant can enter the market without passing a series of standardized bench and OEM hardware tests. Having accomplished both of those milestones, Lubrizol 5703 has established itself as a well-known additive package. Then Lubrizol’s hydraulic fluid development team combined it with a specially designed performance polymer called Lucant, which helped maintain durability in the Eaton 35VQ vane pump test. The end-of-test weight loss measurement clearly stays within the published test limit (Figure 2). In addition to providing critical wear protection, Lubrizol’s hydraulic energy-efficient offering also delivers lower operating temperatures by up to 17% in industry pump rig testing. This additional benefit is a consequence of reduced fluid friction, or traction, delivered by the Lucant line of performance polymers. We have evaluated the traction coefficient of a commercially available HF-0 approved multigrade fluid and compared its frictional properties to Lubrizol’s efficient HV (multigrade) solution. By deploying molecules known to reduce fluid friction, in this example by as much as 9%, reduced operating temperatures and greater fluid flow through the network of pipes and bends of a hydraulic system can be realized. With cooler-running hydraulic systems comes related oil-drain life-increasing performance. One indicator of the real-world ramifications of reduced operating temperature is the generation of oxidation products, such as sludge. Lubrizol’s enhanced thermal stability performance reduced sludge. In an industrystandard sludge test, a 96% reduction in sludge was observed, offering another example of extended oil life and system durability. As companies decide whether to change from a monograde hydraulic fluid to a multigrade one, they must consider the stay-in-grade shear stability of the viscosity modifier. In the case of Lucant, that means it not only maintains appropriate multigrade, lowtemperature performance while staying durable, but it also offers more protection than more conventional multigrade viscosity modifiers. In Figure 3, the 200hour KRL bearing shear test data proves the improved shear performance of Lubrizol’s total hydraulic solution. As can be seen, it stayed well below the 15% viscosity loss threshold three times longer than a conventional multigrade hydraulic lubricant. Saving energy saves money

To confirm and quantify the energy savings, Lubrizol authorized real-world field trials. Using an offhighway wheel loader, a mobile field trial showed diesel fuel savings of 1.4% to 2.7% depending on when and where it was used, as well as the ambient 44


8 • 2021

Figure 4. A mobile field trial showed diesel fuel savings of 1.4% to 2.7% depending on when and where it was used, as well as the ambient temperature of the air.

temperature of the air (Figure 4). It also tested its combined fluid in a stationary hydraulic injection molding machine, where the Lucant-containing lubricant showed an 8.5% reduction in electricity consumption (Figure 5). Confirmation comes in the lab

Though the field trial results were certainly promising, confirmation from lab results were in order. Lubrizol’s hydraulic fluid development team set out to run other experiments in a controlled lab environment, specifically to eliminate the constraints and variables inherent to field testing. To that end, the team created Lubrizol’s Total Hydraulic System Efficiency Rig, which did just that. Originally designed to imitate a real-world skid steer, the rig also contains the essential elements of a hydraulic system. In addition to hydraulic pipes, hoses, and valves, the rig incorporates an off-the-shelf commercial piston pump that supplies a hydraulic circuit. In addition, the rig can be configured in different ways because of its modular design, which allows for more extensive testing than can be done in field tests. Efficiency testing, done over the prescribed condition set, was designed to capture the diverse duty cycles and system requirements of a skid steer. The rig was provided a significant number of flow, pressure, and temperature sensors, which allowed researchers to do exhaustive future-looking hydraulic efficiency research. First, however, it was used to corroborate the efficiency gains seen in the field with the use of Lucant and Lubrizol 5703. 8 • 2021





In Figure 6, it can be seen that the Lucant fluid improved efficiencies over both a monograde (3.8% better) and a conventional multigrade lubricant (1.6% better). How does it work?

Lubrizol 5703, combined with the Lucant performance polymer, provides substantial efficiency gains both in the field and in the lab, but at a molecular level, what is its mode of action? Lubrizol, in partnership with university researchers, discovered that it presents unusual performance benefits that are not available in other more conventional hydraulic viscosity modifiers. As a result of its distinct molecular structure, Lucant lowers the number of parasitic losses that occur when fluid flows around bends, twists and turns, or through valves, filters and other nonlinear hardware flow paths. Figure 1 illustrates a secondary flow field (denoted by the arrows) as a fluid navigates a 90° bend. While conventional hydraulic viscosity modifiers do not always reduce the intensity of these secondary flow vortices effectively, Lucant can and does by forming small, flexible chains with respect to their overall contour length. Its large extensibility parameter provides viscoelastic behavior. In contrast, conventional viscosity modifiers contain long sidechains and short backbones to prevent tight coiling and reduce flexibility. Those characteristics reduce their extensibility and provide no detectable viscoelastic effect. Lucant’s viscoelastic chains accumulate and remove energy from the coherent vortices, which lead to their decay. Reducing fuel consumption is the key to saving money over the long term, and Lubrizol’s total hydraulic solution helps reach those monetary goals through reduced fuel consumption in mobile equipment and electricity savings in stationary systems. That is not the only savings it produces, however — it can also help save the Earth. Using a total hydraulic solution can combat climate change by reducing carbon dioxide and resource consumption, thereby improving the environment for future generations and promoting greater sustainability within the lubricant industry itself.

Figure 5. Tests were also done in a stationary hydraulic injection molding machine, where the Lucant-containing lubricant showed an 8.5% reduction in electricity consumption.

Figure 6. The Lucant fluid improved efficiencies over both a monograde (3.8% better) and a conventional multigrade lubricant (1.6% better).


Lubrizol 46


8 • 2021

Smart Hydraulics. Easy Business. Visit HAWE at these trade shows: 9.13 - 9.15 Booth 1467 Las Vegas, NV

9.28 - 9.30 Booth A1520 Louisville, KY

Register now for HAWE’s online Event on 10.14! Why should you attend? • Learn about small compact power units • Virtual 3D products and environment • Launching of two new HAWE products

• • • •

Production factory tour Applications examples Break-out sessions Live Q&As and chat feature

When great things are being moved with hydraulics, HAWE is involved.

HAWE Hydraulik is a leading manufacturer of technologically advanced, high-quality hydraulic components and systems. HAWE products are used wherever high quality, high power and maximum precision is required - whether in mining and drilling equipment, construction machinery, CNC machines or wind turbines.

Partner with HAWE to always have the right solution! | | 704-509-1599

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6/29/2021 3:44:41 PM

PackExpo returns with in-person event The event is slated for Las Vegas Convention Center September 27-29. Edited by Mary C. Gannon • Editor 48


8 • 2021




PACK EXPO Las Vegas and Healthcare Packaging EXPO 2021, slated for September 27-29 at the Las Vegas Convention Center, are ready to welcome the industry back together at the only comprehensive packaging and processing event in the world this year. “We continuously monitor the industry, and exhibitors and attendees alike are eager to return to conducting business and experiencing new machinery, materials, technologies and solutions in-person,” said Jim Pittas, president and CEO of show producer, PMMI, The Association for Packaging and Processing Technologies. “There is no substitute for seeing technology up close, manipulating materials and containers, experiencing controls systems, speaking to multiple vendors and getting answers on the spot.” PACK EXPO Las Vegas and Healthcare Packaging EXPO is the only show this year covering the entire packaging and processing industry spread across four expansive convention center halls. More than 1,500 exhibitors will showcase the latest new materials, technologies and solutions to address the packaging and processing needs of over 20,000 attendees from 40-plus vertical markets. See a list of current fluid power exhibitors on page 50. The state of Nevada recently reinstated its mask mandate for public indoor settings so masks will be required throughout the exhibit halls. “In the planning of PACK EXPO Las Vegas and Healthcare Packaging EXPO, we recognize that information and guidelines will change constantly and have committed to updating our approach in line with CDC and local regulations, along with industry best practices,” said Laura Thompson, vice president, trade shows, PMMI. “Many events have already safely taken place, and we have taken best practices from those events along with current government guidelines to implement the PACK Ready health and safety plan for a successful in-person event.” Spaced across four large convention center halls, PACK EXPO Las Vegas offers countless opportunities for ideas from 40-plus vertical markets to cross-pollinate. Healthcare Packaging EXPO provides the broadest range of equipment and technology solutions for life sciences, showcasing targeted solutions for pharmaceutical, medical device, nutraceuticals and biologics. “Our industry’s essential role over the past year shed light on new technological needs, and these improvements and advancements in equipment and technology will continue to evolve,” said Thompson. “Walking the aisles, connecting with colleagues and meeting new people will allow attendees the opportunity to discover solutions they didn’t even know they needed.” Free educational sessions located throughout the exhibit halls will provide chances to grow, learn and accomplish professional goals with suppliers showcasing breakthrough technologies, best practices and case studies at the Innovation Stages. The Forum, an interactive stage encouraging open discussions with industry experts; the Reusable Packaging Stage, hosted by the Reusable Packaging Association; and the new PACK to the Future Stage are also must-visit show floor destinations to learn about the latest trends and discuss the future of the industry. PACK EXPO Las Vegas 2021 will also feature the return of the Processing Zone with solutions from food processing/systems, food safety, engineering, design and construction services and more. Attendees can once again start their search for front-of-the-line processing solutions while continuing to solve their packaging challenges all under one convenient roof. A processing-specific Innovation Stage will also feature sessions targeting the processing sector. In addition to PMMI provided networking, 19 association partners have signed on to support and exhibit at Las Vegas, with many offering opportunities for their members to connect during the show, including CPA, the Association for Contract Packagers and Manufacturers, Institute of Packaging Professionals (IoPP), Foil & Specialty Effects Association (FSEA), OMAC-The Organization for Machine Automation and Control, Flexible Packaging Association and more. Registration, which includes access to both PACK EXPO Las Vegas and Healthcare Packaging EXPO, is $30 until September 3, after which the price increases to $130. For more information and to register online, visit and FPW

8 • 2021




Las Vegas, Nevada | September 27-29, 2021

Exhibitor List Exhibitor




ACE Controls Inc.


Graco Inc.


Adsens Technology Inc.




AF Compressors


J.W. Winco Inc.


Airtac USA Corp.


Lubriplate Lubricants


Alkon/Allenair Corp.


Motion Industries


Autonics USA Inc.


New Age Industrial


Bimba Manufacturing Co.


Piab Inc.


Burkert Fluid Control Systems


Posital Fraba


Busch Vacuum Solutions






Schmalz Inc.


Coval Vacuum Technology Inc.


SIKO Products Inc.


DVP Pumps Inc.


Smalley Manufacturing Co.


Elesa U.S.A. Corp.


SMC Corporation of America




Tolomatic Inc.


Festo Corporation


U.S. Tsubaki Power Transmission




VacMotion Inc.



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Rescheduled MinExpo to open in Vegas in September

The event, which was postponed due to Covid-19 last year, is set for September 13-15 at the Las Vegas Convention Center. Edited by Mary C. Gannon • Editor



8 • 2021

After being postponed due to Covid-19 last year, MinExpo will return to

the Las Vegas Convention Center September 13-15, featuring 11 halls of industry suppliers showcasing the latest products and services for mining. The three-day event brings together manufacturers, global suppliers, and start-ups to highlight exploration, mine development, open pit or underground mining, preparation and processing, smelting and refining, environmental compliance, safety, reclamation or mine closures, and more.

The event features about 1,500 exhibitors from 30 countries covering more than 666,000 square feet, with more than 70 companies highlighting key technologies for fluid power systems. Mining sectors represented include precious, nonferrous and ferrous metals, coal, industrial minerals, stone mining and quarrying, and sand and gravel. Attendees include production/operations/ maintenance personnel, engineering and geology professionals, environmental staff, management and personnel active in the approval and procurement chain. It will allow attendees to:

• Purchase equipment, parts and services from current vendors and discover new sources. • Experience first-hand innovative and cutting-edge products: sensors, advanced instrumentation, AI, robotics, automation, mobile technology, data analytics and more. • Collaborate with technical staff on the show floor to address operational issues and challenges. • Participate in expert led sessions focusing on today’s relevant issues with information you can use now and for strategic planning.

Start Where You Are — Coeur Mining’s ESG Evolution — Casey Nault, Senior Vice President, General Counsel and Secretary, Coeur Mining Inc.

The number of education sessions has been limited this year to use larger rooms and to ensure proper cleaning of the rooms between sessions. Education will kick off with the opening panel discussion at 10 to 11:30 a.m. Monday, September 13, with representatives from Barrick Gold Corp., CONSOL Energy, Komatsu Mining, Caterpillar, Arch Resources, and Freeport-McMoRan Inc.

Safety — Tuesday, Sept. 14, 8:30 – 9:45 a.m.; South Bldg., Room 219

Leveraging Innovation to Promote a Sustainable Future for Coal — Jacquie Fidler, Vice President, Environmental & Sustainability, CONSOL Energy Inc. Rethink the Machine, Not the Mine — Brian Huff, Vice President of Technology, Sandvik BHEV Business Unit

Impwroving Safety by Utilizing Predictive Analytics to Manage the Human Factors Component — Marcus Wichmann, Vice President of technical services, Predictive Safety

Additional sessions will include the following tracks and topics: ESG in Mining — Monday, Sept. 13, 2-3:15 p.m., South Bldg., Room 219

Today’s Generational Workforce — How it is

Changing Safety in the Mining Industry — Walter Simpson, Manager - Safety, Training & Professional Development, NACCO Natural Resources

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8 • 2021





What a New Silica Standard in the U.S. May Look Like — Michael Wegleitner, Corporate Director, Safety and Health, Hecla Mining Co.


Las Vegas Convention Center | September 13-15

Exhibitor List Exhibitor



Diversity, Equity and Inclusion — Tuesday, Sept. 14, 2-3:15 p.m., South Bldg., Room 219

A.W. Chesteton Accumulators


Motion Industries Inc.

The Changing Faces of Mining: Diversity is Key, But Inclusion Makes the Real Difference — Kathryn Jacobs, Managing Director, North America Mining Lead, Accenture

AKG of America Inc.


Movo Hydraulics


No Limit Oil Filtration Technologies LLC


North American Hydraulics


Parker Hannifin Corp.




Petro-Canada Lubricants Inc.


Freeport Edge: Building Our Inclusive and HighPerformance Culture — Shannon Lijek, Vice President of Transformation and Organizational Development, Freeport-McMoRan Inc. Power of Everyone — Karl Weiss, Vice President, Integrated Components and Solutions Division and Chief Technology Officer, Caterpillar Inc Environmental Challenges — Wednesday, Sept. 15, 8:30 – 9:45 a.m.; South Bldg., Room 219


Austin Hose


Bonfiglioli USA


Bosch Rexroth


Carlisle Brake & Friction


CD Industrial Group




Chevron Lubricants


CN Hydraulic Parts






Dellner Bubenzer


Delval Flow Controls USA


Understanding Key Air Quality Aspects and Strategies for a New Mine Development — David Strohm II, Managing Consultant, Trinity Consultants Inc.



Eastern Pneumatics & Hydraulics


Eaton Corp.


Implementation of the Global Industry Standard on Tailings Management: An Operator’s Perspective — Kim Morrison, Sr. Director Global Tailings Management, Newmont Water Management in Nevada as Part of our Commitment to Sustainability — Patrick Malone, Vice President, Barrick Gold Corp.





Famic Technologies Inc.


Festo SE & CO. KG




Force Control Industries Inc.


Artificial Intelligence — Wednesday, Sept. 15, 10:30 – 11:45 a.m.; South Bldg., Room 219

Fuchs Lubricants Co.


GPM Inc.


Applied R&D in Mining Robotics at the National Robotics Engineering Center: Systems, Lessons, and Perspectives — Dimitrios (Dimi) Apostolopoulos, Ph.D., Senior Systems Scientist, Robotics Institute, Carnegie Mellon University, and Program Director, National Robotics Engineering Center (NREC)

GS Global Resources


Hannay Reels Inc.


The Next Phase of Data Analytics for Mining — Stephen Redford, President, Matrix Analytics Group The Award Event will be held on Tuesday Sept. 14 from 11:15-1:15 p.m. The award recognizes 2019, 2020 and 2021 outstanding achievements in the areas of mine safety, technology, and environmental stewardship by U.S. mining companies. An attendee FAQ will be available at the MinExpo website in the coming weeks. For more information, visit

HAWE Hydraulics HBC-Radiomatic Inc.

1467 24421

Hercules Sealing Products


Hilliard Brake Systems


Hydra-Tech International Corp.




J.R. Merritt Controls


John Crane


Libherr Mining Equipment


Manuli Hydraulics








8 • 2021


Polygon Composites Technology

8201 961


PSP Seals


Quaker Houghton


RAM Enterprise


Rota Engineering Ltd.


Schroeder Industries


Seal Source Inc.


SMC Corp. of America


Spencer Fluid Power


SPX Flow


Staubli Electrical Connectors Inc.


TE Connectivity


Texas Hydraulics




Tribco Inc.


U.S. Tsubaki


Vanair Manufacturing Inc.






Voith Turbo


WIKA Instrument LP


Wooster Hydrostatics Inc.


Xtended Hydraulic and Machine


making a difference

FOR YOUR BUSINESS Our cutting-edge line of hydraulic hose and fittings is not just a product division. It’s a promise of superior service, quality, technical support and availability. We’ve built our company on impeccable customer service. Let us know how we can make a difference for your business. call 800.231.7116 or email




Utility Expo

to open with higher attendance than previous years The renamed ICUEE event for those in the utility equipment industry is slated for September 28-30 at the Kentucky Exposition Center in Louisville. Edited by Mary C. Gannon • Editor



8 • 2021

The Utility Expo (formerly known as ICUEE), will open its doors at the Kentucky Exposition Center on September 28-30 with attendance currently being 20% higher than the event in 2019. The event will feature a new outdoor show layout, designed to allow for more product introductions and demonstrations than ever before. The demolition of Old Cardinal Stadium from the Kentucky Exposition Center grounds allows The Utility Expo to use that newly paved lot for exhibits, serving as a massive contiguous exhibit area connecting the indoor exhibits in North Hall and the traditional digging space in Lot K. The new layout also provides for the opportunity to group similar product types, making it easier to navigate and find the equipment at the show. Ultimately, this reimagined and optimized exhibit space will lead to better show traffic flow and make the movein process easier for all show exhibitors. According to John Rozum, Show Director, The Utility Expo, the event remains what it’s always been: the premier event for industry professionals to see, touch, hear and learn about the latest tools and cutting-edge technology impacting their jobs. The Utility Expo show floor has expanded to nearly 1.32 million square feet and will welcome over 800 manufacturers and service providers in the industry, including several key manufacturers in the fluid power space. See exhibitor list on page 58 for details on current hydraulics and pneumatics exhibitors. The Utility Expo, known for attendees’ ability to test drive equipment, attracts professionals from all utility sectors. Field classrooms walk the show floor and share best practices on equipment utilization and identifying key features that may bring value to your business. Each class earns 1.5 professional development hours. Several topics are relevant to users and designers of fluid power systems including Equipment Hydraulics, where users will learn how to understand the variety of hydraulic systems and the best applications for each, how to evaluate your company’s needs to select the right hydraulic system and gain key insights on a comprehensive maintenance program and the best oil type for your workflow. Other sessions include fleet management, safety, and more. Each 90-minute field classroom is $129 with the purchase of any badge. The event also includes 50 on-demand training options that are available throughout the year starting October 1. Visit for more details and to register.

Improve Efficiency and Performance with Low Power Valve Technology Emerson offers ASCO™ low power solenoid valves that enable lower operating costs, support remote operations, and minimize drain on power sources. With wattages as low as 0.48 watts, these valves deliver precise actuation, unrivaled reliability and energy efficiency for a variety of applications in the process, industrial, and commercial industries. Learn more at:


8 • 2021


The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2021 Emerson Electric Co.


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Kentucky Exposition Center, Louisville | September 28-30

Exhibitor List Exhibitor ASA Hydraulik of America Atlas Copco Power Technique






Lillbacka USA



MP Filtri USA Inc.


Bailey International LLC


Muncie Power Products


Bondioli & Pavesi Inc


NBB Controls Inc.


Bucher Hydraulics Inc.


Next Hydraulics S.R.L.


Casappa Corporation


North American Hydraulics, NAHI LLC


Continental Hydraulics


OTTO Controls




Parker Hannifin Corporation


CRC Industries


Permco Inc.


Dinamic Oil North America


Polygon Composites Technology


Dixon Quick Coupling


Reelcraft Industries Inc.


Doering Company


Rota Engineering


Dynamic Fluid Components Inc.


Salami SpA


Dynatect Manufacturing Inc.






Stucchi SRL


Eaton Corporation


Suco Technologies


FORCE America Inc.


Sun Hydraulics LLC


GS Global Resources Inc.


Sunfab Hydraulics


Hannay Reels Inc.


Sure Grip Controls Inc.


Harrison Hydra-Gen


Texas Hydraulics Inc.


HAWE Hydraulik


The Lee Company


HBC-radiomatic Inc.


Thomas Magnete USA LLC


HED (Hydro Electronic Devices) Inc.


Vanair Manufacturing Inc.


Holmbury Inc.




HYDAC Technology Corporation/Schroeder Industries


Vitillo USA





E815, A1401

IC-Fluid Power Inc.


WIKA Mobile Control


Joral LLC



8 • 2021

numbers don’t lie

72 PE2101 Liquid Power_August.indd 1

108 YEARS operating continuously as a family business 72 YEARS providing hydraulic pumps, motors and accessories #1 QUALITY #1 DEPENDABILITY



If you like our numbers, you’ll love our products. Contact us now for a distributor near you. | (800) 626-2801

7/14/21 12:09 PM


Hydraulic hose with wire-braid technology   MEGASys MXT with XtraTuff Plus cover (MXT-XTP) is a universally applicable hydraulic hose with patent-pending wire-braid technology. MXT-XTP offers all the benefits of the MXT hose — compact size, lightweight, flexibility, and high performance — with added durability from the XtraTuff Plus (XTP) cover. This lightweight, high-performance MXT hose has been proven in the factory and field worldwide, being specified by OEMs and used repeatedly by replacement channels. It’s 25% lighter than conventional hoses, making it easier to lift and handle, plus MXT is up to 49% more flexible, allowing faster and more ergonomic installations. The MXT hose now has an optional XTP cover, maintaining MXT hose performance while adding 25 times the abrasion resistance and enhanced ozone resistance, as validated by a rigorous 800-hour ozone exposure test. The XTP cover was previously introduced as the standard cover on MXG 4K. MXTXTP hose meets or exceeds relevant ISO, SAE, and EN performance standards, is MHSA-certified for flame resistance, and is certified leak-free per SAE J1754 when used with Gates MegaCrimp couplings.

Fluid purifier system

Hydraulic oils for marine applications

  This optimized version of the IFPM 33 mobile, off-line fluid purifier system is a fully-automated, PLC-controlled purifier that removes free, emulsified and dissolved water, free and dissolved gases, and particulate contamination down to 3 µm from light transformer oils to heavy lubricating oils at a flow rate of 8 gpm (30 lpm). Typical high-moisture applications include hydroelectric power, pulp and paper, offshore, and marine. The purifier contains a filter element of the NR630 series according to DIN 24550-4 and guarantees fluid filtration in addition to dewatering. The fineness of the filter element can be selected according to market standards, for example, 10VG element with ß200 = 10 µm(c). These VG media are multi-layer, pleated constructions made of glass fiber fleece with a high retention rate of fine dirt particles at constant performance over the element lifetime and high dirt-holding capacity. Equipped with Viton seals, these filter elements are well-suited to support dewatering.



8 • 2021

  Mobil SHC Aware HS series high-performance hydraulic oils meet Vessel General Permit (VGP) requirements for environmentally acceptable lubricants and EU Ecolabel requirements while offering excellent protection in hydraulic systems. Biodegradable, minimally toxic, and nonbioaccumulative, these lubricants can be used in hydraulic systems where spills or leakage could result in adverse environmental impact. The line includes Mobil SHC Aware HS 22, 32, 46, and 68 grades. These lubricants are suitable for various marine applications, including hydraulic deck equipment, winches, ramps, hatches, doors, cranes, and other hydraulic pumps. Potential benefits: • An all-around balanced formulation, enabling protection and performance at a wider operating temperature • Cleanliness and deposit control • Superior low-temperature startup • Outstanding demulsibility, which eases water removal in critical applications • Compatibility with most common elastomers and seals

Series-production range for piston accumulators   

Festo’s round cylinder DSNU-S The most slender and shortest round cylinder in the market!

Piston with integrated elastic cushioning element

To complement its lines of hydraulic cylinders, hydraulic power units, and gas cylinders, Liebherr has created a series-production range for piston accumulators. The series stands out due to modern and economical production processes and a lowmaintenance and compact design. They are available in a range of piston diameters from 100 to 360 mm, with oil volumes of up to 400 l. The design and production of the piston accumulators meet country-specific requirements in line with PED 2014/68/EU and ASME Code Section VIII regulations. The production range offers a selection of different oil and gas connections. Furthermore, there is an option to integrate a position transducer system. Depending on the requirements, the products can be primed, painted, or coated for salt-water protection. The solutions in the series-production range are designed for both mobile and stationary applications. They find their use in industrial applications, mobile machines, in the field of renewable energies, as well as in maritime and offshore applications. In this context, they can be applied for energy storage and emergency operation but also for shock absorption. In the system, the piston accumulators of the new production range can be integrated into vertical and horizontal installation positions. In use, the components can withstand temperatures from –40° to 90°C.

Piston with magnet for sensing standard

Space optimized

Self-adjusting pneumatic cushioning PPS Seal for piston rod and piston made of PUR

Label with product-key Barrel made of stainless steel

Piston rod made of stainless steel

Threads for direct mounting

The DSNU-S is part of the Festo Core product range in stock and ready for delivery today!

Quick delivery.

In stock worldwide.

which means it’s







Air picker and air gripper components    KOGANEI has added the Air Picker and Air Gripper (Bridgestone Series) components to their selection of pneumatic grippers. These versatile rubber end effectors are designed to handle workpieces securely, gently, and with precision. The Air Picker and Air Gripper have numerous factory automation and warehouse applications, including picking, transporting, and loading products, as well as sealing and stopper fitting. Advantages: 1. Larger contact area provides more secure, precise, and gentle holding for fragile objects. 2. Significantly lighter and capable of carrying a load 25 to 100 times their own weight. 3. Multiple workpiece sizes can be handled with the same unit — no need to change gripping chuck for each product diameter.


Hydraulic plug and cap line expansion Rod Locks

Increased Safety for Processes & Machines •


Designed and built specifically for almost all pneumatic cylinders or round shafts and rails •


With guide rod systems and NFPA or ISO pneumatic cylinders •



  To continually update and add to its range of products, MOCAP is expanding on its offerings of the following plugs and caps: T Series Tapered Plug Caps, which are dual-function closures that can be used as a cap for hydraulic fittings, tube end cap, or pipe cap, or can function as a plug for threaded holes, fittings, or ports. FC Series Flanged Caps are designed to protect threads, components, or fittings, with many new diameters and extended lengths now available. In addition, MOCAP introduced the brand-new OP Series Outside Pull Tapered Plugs, which give customers a choice when their application requires a snug fit, but easy removal of the plug. This is attained with the tapered plug design and the offset pull-tab. All MOCAP parts are available in stock for immediate shipment in box, mini-pack, and micro-pack quantities.

Select yours at or call 800.843.7445 62

Nexen NexSafe Ads-Design World-1/3pg REV04.21.indd 2

4/12/21 11:57 AM


8 • 2021

COMPONENT FOCUS Vicki Burt • Contributor

How do you mount/install a compact pneumatic cylinder? One of the benefits in choosing a compact cylinder is getting effective motion in a small footprint. These short-stroke, lowprofile, air cylinders are designed to fit into tight spaces and are available in a variety of mounting options. Pancake cylinders are a trademarked line of compact air cylinders from Fabco-Air Inc. They were designed in the 1950s to get the longest stroke possible in the smallest envelope and have evolved to include a variety of bore sizes and options such as magnetic pistons and non-rotating styles. Designers need to consider the cylinder’s primary function and the available space when deciding what kind of mount to use. Don’t forget that many manufacturers will also work with you directly to either help optimize a standard mount or create a custom set-up. Here’s a look at installation options for some of the most widely used compact air cylinders. The type of mount selected will depend first on whether the motion is linear or turns a crank arm. For linear motion along a straight line, including pushing, pulling, or lifting, select a rigid mounting. This could mean bolting the cylinder by tapped holes on the bottom or standing it on end and running bolts into sleeve mounts in the end cap. Standard NFPA mounts are usually available from the manufacturer. For motion that turns a crank arm where the cylinder needs to pivot, select flexible mounting. Clevis mounts, eye mounts, and trunnion mounts allow the cylinder to move in an arc while restricting lateral motion. Another consideration is where the

cylinder will be supported, for example, directly down the centerline, at a pivot point, or using a foot mount. In centerline mounting the mounting plane is the centerline of the cylinder. Thru-hole, nose, and rear-flange mounts are examples of centerline mounts. In non-centerline mounting, the plane is not through the centerline of the cylinder, which can create a bending moment around the mounting points. Side lug and foot mounts are a few of the options for these applications. For applications where the cylinder’s piston rods need support at its extended length, there are several ways to design for this. An internal stop tube can block the piston from reaching the front head, reducing wear and extending operating life. Double rod cylinders have rod bearings in both end caps reducing the load on the piston. And twin rod cylinders can be installed vertically or horizontally to support large loads. Compact air cylinders are designed to fit into tight spaces while providing long strokes. Working with the cylinder manufacturer will get the best fit for your application.

Festo’s ADN-S series of compact cylinders are extremely small and light and deliver excellent performance with small movements.


Here, Festo’s ADN-S cylinders are used for long-term testing of smart phones.

8 • 2021




Ace Controls .....................................27 ALA Industries ..................................11 Ametek APT......................................39 AutomationDirect .............................. 1 Barb-Tech Tools ................................17 Clippard ............................................BC DMIC ..................................................7 Doering Co. ......................................29 Emerson ...........................................57 FESTO ...............................................61 FluiDyne Fluid Power .......................45 HAWE Hydraulic ...............................47 HBC-Radiomatic ...............................53 Hydraulex Global ..............................51 Hydraulics Inc ...................................15 Main Manufacturing .......................... 8 Motion .............................................23

MP Filtri USA ...................................... 5 Nexen Group ....................................62 Peninsular Cylinder Co .....................19 Permco, Inc. .....................................59 Polyconn ...........................................33 Proportion-Air ..................................50 Spartan Scientific .............................28 Stauff Corp. .....................................IBC Super Swivels ...................................40 Taimi Hydraulics ...............................13 Texcel Rubber ...................................55 Tompkins Industries .................... IFC, 8 Ultra Clean Technologies .................41 Veljan Hydrair...................................35 Vermatic Inc. ...................................... 3 Zinga - Filtration Group....................... 9

LEADERSHIP TEAM Co-Founder, VP Sales Mike Emich 508.446.1823 @wtwh_memic Co-Founder, Managing Partner Scott McCafferty 310.279.3844 @SMMcCafferty EVP Marshall Matheson 805.895.3609 @mmatheson


Follow the whole team on twitter @FluidPowerWorld

Let us connect you with industry leading advertisers Which of the above companies interest you in this issue? Follow the below steps and learn more about their products. Circle above advertisers of interest. Please fill in your name, company, email address or enter your 9 digit subscriber number Name: ___________________________________________________________________ Company: ________________________________________________________________ Email: ___________________________________________________________________ Subscriber number: ________________________________________________________ Please send your response via email to or fax it to 888.543.2447 64


8 • 2021

The STAUFF Difference

At STAUFF we offer thousands of critical components that that are designed to help our customers operate more efficiently and do business more effectively.

Quick Couplers • Pressure Testing • Clamps • Filters STAUFF Corporation P 201.444.7800

STAUFF Canada Ltd. P 416.282.4608

Stauff_FP_Print.indd 1

Contributing to Your Success

7/2/21 12:13 PM


Control Solutions Designing efficient systems involves much more than simply understanding a few basic principles. There is a true art to balancing the specific requirements of an application in order to achieve the desired goals in the best possible way. Help us understand the unique needs of your application and together, we’ll develop something that surpasses what any of us could have done alone. Contact your distributor to learn more, or visit to request a free catalog and capabilities brochure.

• • • •

Electronic Valves Proportional Valves Isolation Valves Precision Regulators

• • • •

Toggle & Stem Valves Needle Valves Electronic Pressure Controllers Pneumatic Assemblies

• • • •

Special Manifold Designs Pneumatic Circuit Design Cylinders Fittings, Hose & Tubing


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Page 24: “Infinite” cylinder upgrades timber logistics Page 42: Optimizing hydraulic fluids with the right additives Page 30: Achieve a gree...


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