Custom Hydraulic Power Unit

Non-Standard System Design

Every hydraulic power unit is designed and manufactured specifically to meet the final operating requirements of each customer. No over-specified catalogue units, no compromised performance — just a hydraulic power unit that fits your machine perfectly from day one.

Integrated Manifold Blocks

The manifold block is configured in line with the hydraulic circuit, dramatically simplifying system piping and reducing the number of potential leak points. Maintenance teams appreciate the clean, accessible layout — particularly in confined plant-room environments common across UK manufacturing sites.

Compact, Space-Saving Footprint

Structural compactness is central to our design philosophy. Whether the installation footprint is dictated by an existing machine bed or a new OEM frame, our custom hydraulic power unit is modelled to occupy the minimum practical envelope without sacrificing cooling area, filter accessibility, or component serviceability.

Premium Hydraulic Valves

All hydraulic control valves fitted to our custom HPUs are selected from high-grade brands and can be substituted or upgraded at the client’s request. Proportional valves, pressure-compensated flow controls, counterbalance valves, and load-sensing arrangements are all accommodated within the standard design process.

Thermal Management Options

Coolers, heaters, and accumulators can all be incorporated during the design phase. For UK clients operating outdoor or unheated facilities, pre-heat circuits ensure reliable cold-start performance, while air-blast or water-cooled heat exchangers keep fluid temperature stable during continuous-duty cycles in summer.

Electrical Control Integration

Electrical control panels, PLC interfaces, and solenoid valve wiring are available as fully integrated deliverables. Boom Cylinders can supply the custom hydraulic power unit complete with a CE-marked control enclosure, reducing the number of separate contractors involved in machine commissioning and ensuring full electrical compatibility from day one.

Working Principle

An electric motor drives a hydraulic pump, which draws fluid from the reservoir, pressurises it, and delivers it through the manifold block to the actuators. Relief valves maintain system pressure within design limits. Return flow passes through filters and, where fitted, a heat exchanger before re-entering the reservoir. The closed-loop circuit ensures continuous, controlled power delivery with minimal energy loss.

Materials

Reservoir tanks are fabricated from welded mild steel plate with internal shot-blast and epoxy coating, or in stainless steel for food-grade and offshore applications. Manifold blocks are precision-machined from high-tensile ductile iron or aluminium alloy, selected according to system pressure and weight constraints. All external pipework is seamless carbon-steel tube or SAE-rated hydraulic hose with crimped end fittings, ensuring zero-leak performance.

Working Medium

We recommend ISO VG 46 antiwear hydraulic fluid for most UK industrial environments. For applications in high-temperature areas — foundry presses, glass-forming machinery, or summer-intensive outdoor plant — ISO VG 68 antiwear hydraulic fluid is recommended to maintain correct viscosity and film strength at elevated operating temperatures. Biodegradable ester-based fluids are supported for environmentally sensitive installations.

Application Sectors

Custom hydraulic power units supplied by Boom Cylinders serve metal-forming and press shops, automated assembly, waste-handling and compaction plants, marine deck equipment, renewable energy (including pitch and yaw systems for offshore wind), quarrying and aggregate processing, and agricultural equipment manufacturers operating from sites across England, Scotland, and Wales.

You Have a Hydraulic Schematic

Send us your hydraulic circuit diagram. Our engineers check it for completeness and accuracy, then manufacture the custom hydraulic power unit precisely to the schematic — no guesswork, no unapproved modifications. Preferred for OEM clients and projects with fixed performance targets.

No Schematic — Start from Requirements

Provide the working cycle parameters: loads, speeds, stroke lengths, duty cycle, and ambient conditions. Boom Cylinders will produce a proposed circuit schematic, confirm it with you, and then build the custom hydraulic power unit — a fully design-and-build service that suits end-users and plant-engineering teams who lack in-house hydraulic design resource.

Copy or Improve an Existing Unit

If you have an existing hydraulic power unit — perhaps from a machine that is being upgraded, or a competitor’s unit that needs replacing — contact us for a sample inspection. Clear photographs of each sub-assembly allow our engineers to identify every component, recommend any improvements, and manufacture a direct replacement or enhanced version.

“We had a very specific envelope constraint and a tight commissioning window. The team at Boom Cylinders came back with a workable design within three days, and the unit arrived pressure-tested and fully documented. We were running production within 48 hours of delivery.”

James H.

Engineering Manager — Automated Assembly, East Midlands

“Our offshore deck crane project required a stainless-steel reservoir, a heating circuit for cold-start, and full ATEX-rated electrical components. Boom Cylinders handled all of that without us having to manage multiple sub-contractors. Excellent supplier for challenging hydraulic specifications.”

Fiona M.

Procurement Lead — Marine Equipment, Aberdeen

“We supplied only a cycle description and a target force — no schematic, no drawings. The engineers sent us a proposed circuit within a week. After one round of comments the design was locked, and the finished custom hydraulic power unit exceeded our cycle speed target by a comfortable margin. Solid company to work with.”

David T.

Plant Manager — Waste Compaction, Greater Manchester

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Full Design Service

In-house hydraulic engineers create circuit schematics, manifold designs, and mechanical arrangement drawings — reviewed and approved by the client before manufacture begins.

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Flexible MOQ — From 1 Unit

Whether you need a single prototype custom HPU for a new machine or a repeat batch of 50 identical units for a production line, our manufacturing process scales without compromising quality or lead time.

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Full Test & Documentation

Each custom hydraulic power unit is pressure-tested to 1.5x working pressure, with a full test report, CE declaration of conformity, and operation-and-maintenance manual supplied as standard — meeting UK Health and Safety Executive requirements.

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UK Delivery Network

Regular shipping routes serve England, Scotland, Wales, and Northern Ireland. Express freight options and on-site commissioning assistance are available for time-critical UK projects — contact us to confirm lead times for your location.