Hydraulic Engineering Case Studies

Take a glimpse into the world of Hydraulics Online…

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We work with integrity – and often in confidence. Some of the projects we support will remain confidential forever, and that’s exactly how it should be.

We’re more than happy to work under non-disclosure agreements when commercially sensitive information or innovation is involved. Our word is good: we won’t take your ideas and promote them as our own.

What you’ll find here is just a small, approved snapshot of case studies that showcase our hydraulic engineering expertise in action.

Echo Engineering & Production Supplies, United States

When a hydraulic valve failed on one of Echo Engineering’s die-cutting machines, Project Manager Jason Semmler found himself in a costly “machine down” situation.

“We were losing money every hour we couldn’t use the machine,” Jason explains. “But it was old, and I was worried I wouldn’t be able to find the replacement part I needed.”

 

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Success Story: Materials Handling

Rather than carrying multiple spare parts for different machines, this materials handling equipment provider turned to Hydraulics Online for a smarter, more flexible solution.

“Hydraulics Online designed a solution that could do this for us – and overnight, we went from a six-week lead time to being able to offer a lead time measured in hours.”

 

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A Reliable Hydraulics Supplier 4000 Miles Away

Despite being based on the Caribbean island of Barbados, this roofing and construction manufacturer relies on Hydraulics Online to keep production running smoothly.

“I don’t think Hydraulics Online has ever refused an order or been unable to source what I needed.” –  Ricky, Production Manager.

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Case Study: Heritage Concorde

Concorde is one of the most iconic aircraft in aviation history—so Hydraulics Online was honoured to be selected as the hydraulics partner for Heritage Concorde’s restoration work.

To date, we’ve designed and supplied hydraulic systems to power the ‘droop noses’ on three Concorde aircraft on display across the UK.

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By Royal Appointment, Mark Westaway & Son

When their local supplier couldn’t provide the hydraulic part needed for a hay baling machine, Mark Westaway & Son turned to Hydraulics Online—and found a more robust, reliable solution.

“Hydraulics Online impressed with their speed of service and helpful attitude.” – Chris Tar, General Manager.

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Independent Hydraulic Procurement

This global supply and logistics company specialises in product distribution, contract supply, and fulfilment solutions. In Hydraulics Online, it has found a hydraulic procurement partner that helps it deliver excellent service to its customers.

“Rather than us having to call around different manufacturers, they can quote like-for-like for us. And they have good routes in to those manufacturers- they get the answers we need quickly.”

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From around the corner to the other side of the world, seven days a week, Hydraulics Online is contacted by customers from all walks of life in a wide variety of industries.

Lights, Camera, Action!

In live broadcasting, time is of the essence – and there’s no such thing as a second take. Adrian Croome, founder of Off Road Jib and a veteran of more than 25 years in television, had spent years manually levelling heavy camera rigs between sets and locations. He knew there had to be a better way – but assumed the solution would be too complex or costly to pursue.

“I didn’t know where to start and thought it would be too complicated and way too expensive to make it a reality.”

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Polarfront – The Explorer of the Arctic Sea

Latitude Blanche is a French shipping company founded in 2017 by two graduates of the École Nationale Supérieure Maritime: Sophie Galvagnon and Yann le Bellec. After years of navigating icy waters, they set out to offer a new kind of polar expedition – one shaped by experience, sustainability, and adventure.

When their ship, Polarfront, urgently needed a rare hydraulic fuel feed pump, they turned to Hydraulics Online.

“Quick and precise,” said Yann le Bellec, Co-founder and CEO, summing up the service they received.

 

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Ghost Bus Tours – "Who you gonna call?"

Routemasters are iconic British buses – engineering legends with unmistakable charm. But at over fifty years old, keeping them on the road is no easy task. When the power steering ram failed on one of Ghost Bus Tours’ vehicles, David, Head of Transport, was told by several suppliers it “couldn’t be repaired.”

In search of a second opinion, he contacted Hydraulics Online.

“After speaking with them, I knew these guys knew what they were talking about… The service was quick. The pricing was good. The quality was good. It was spot on.”

 

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Success Story: Royal Shakespeare Company

The Royal Shakespeare Company might be used to performances raising the roof – but this time, it needed to lift the stage. When the hydraulic system supporting a major production needed a critical part, Gill Leefe, Control Systems Engineer at the RSC, turned to Hydraulics Online.

“I did call around looking for alternative quotes, but nobody could match Hydraulics Online on price.”

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SpaceX Hyperloop Competition

HypED is a student-led team from the University of Edinburgh blazing a trail for British engineers in Elon Musk’s Hyperloop project – an ambitious vision for ultra-high-speed, sustainable transport. When HypED was shortlisted for the final of the 2017 SpaceX Hyperloop competition in California, they needed hydraulic expertise to bring their braking system from concept to reality.

That’s where Hydraulics Online came in.

“Hydraulics Online helped us take it from concept to a working design that achieved the functionality in a safe and certified manner.”

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Marine and Subsea Hydraulics

Our customer – an international player in underwater cabling – first contacted Hydraulics Online in 2014, when they urgently needed a replacement part for legacy subsea equipment. Their regular supplier couldn’t help, and time was tight.

“I called Hydraulics Online because at that stage I had nothing to lose. I gave them a call and within two hours the team came back to me to say ‘yes, we can source that’. It was an absolute revelation.”

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“We wanted a system that would suit almost every forklift truck manufacturers’ product range, rather than having to order in specific parts to suit specific OEMs; something we could keep on the shelf, knowing we could modify it to suit. Hydraulics Online designed a solution that could do this for us, and overnight we went from having a six-week lead time – as dictated by the ordering and delivery of parts – to being able to offer a lead time measured in hours.”

Technical Director , Materials Handling Equipment Provider

“Hydraulics Online are the only company we’ve come across where we are able to give them these problem scenarios and they come back to us with a solution. They have a vast knowledge of their technology and of system design and, because they are independent and not tied to any one manufacturer, I know they are giving us the best solution and the best products for that solution.”

Technical Director , Materials Handling Equipment Provider

“Because Hydraulics Online is independent and not tied to any one manufacturer, I know that they are giving us the best solution and the best products for that solution.”

Technical Director , Materials Handling Equipment Provider

Case Study: First UK Concorde Droop Nose

The hydraulic systems on Concorde 101 G-AXDN hadn’t been used since her retirement in 1977. But when the Duxford Aviation Society sought to enhance their display at the Imperial War Museum, Heritage Concorde proposed something bold: make her the first UK Concorde since 2003 to “droop” her nose.

To bring “Project Salute” to life, they turned to Hydraulics Online for technical support – and we were proud to help.

“It has been a real pleasure dealing with the team at Hydraulics Online. We couldn’t have asked for more.” – Graham Cahill, Director of Projects, Heritage Concorde.

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Mayday! Mayday! Missing Flight MH370

In March 2014, a Malaysian marine maintenance company approached Hydraulics Online after struggling to source critical hydraulic parts for a Royal Navy vessel.

While other suppliers had found the request difficult, to us, it was a routine enquiry—and we quoted the same day.

Just days later, the situation escalated.

What happened next was anything but routine.

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Case Study: Commercial Hydraulic Pumps

Having peace of mind is key when buying any hydraulic equipment – you want to be able to “fit and forget”. We also understand that sometimes you might actually have needed something yesterday, and that your budget is always being asked to stretch that… little… bit… further.

That’s why we offer a range of completely interchangeable, direct equivalents to the Commercial Hydraulics pumps range. Built and tested here in the UK, you can be assured of a quality product that can, more often than not, be dispatched within 24 hours.

Even if you’re literally stranded on a vessel out at sea – we can take the pressure.

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Greetings from the US Navy Office, Okinawa, Japan!

That was the subject line of an email sent to our technical team from a Marine Surveyor based at the US Navy Office in Okinawa.

The vessel in question – a landing craft mechanical (LCM) used for transporting vehicles – was experiencing limited flow from two Eaton Vickers pumps during operational testing.

Thousands of miles from our UK headquarters, the Navy team needed expert troubleshooting support – and fast.

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From Dinosaurs to Roller Coasters – Discover the Magic of Hydraulics…

Many people don’t realise just how much of the modern world runs on hydraulics – or how this powerful technology continues to drive innovation across industries. From animatronic dinosaurs and amusement park rides to dishwashers and fuel pumps, hydraulics are everywhere.

At Hydraulics Online, we’re not just supplying components – we’re enabling extraordinary experiences powered by fluid. Whether it’s restoring Concorde’s iconic droop nose or supporting student engineers in Elon Musk’s Hyperloop competition, we’re proud to be part of the magic.

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Custom Hydraulic Design Solutions

As many of our case studies show, Hydraulics Online is a trusted partner for custom hydraulic power packs and system design – whether for mobile or industrial applications. From relatively standard units to complex, bespoke systems, we bring award-winning expertise to every project.

Our collaborative, confidential approach gives customers the freedom to explore new ideas and push boundaries – turning engineering concepts into pioneering, real-world solutions.

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We’re a hydraulics hub – offering thousands of possibilities. From urgent repairs to pioneering design projects, we’re here to help. How can we support you today?