Special Projects & Hydraulic System Design
At Statewide Hydraulics, we’re regularly engaged to design, manufacture, and install hydraulic solutions built around our clients’ specific requirements. These projects go far beyond selecting components from a catalogue. They demand research, engineering insight, and a deep understanding of how hydraulics behave in real world conditions.
Our work spans a wide range of industries and applications — from simple, low cost mechanisms to complex, one off builds and OEM level systems. Whether the goal is maintenance, innovation, or a completely unique application, we specialise in creating solutions that work reliably, efficiently, and safely.
Innovation is at the core of what we do. While we often use readily available components, it’s the thinking behind the design — how we combine, configure, and integrate those components — that sets our systems apart. A great hydraulic system is never just about the hydraulics; it’s about understanding every factor that influences performance, longevity, and usability.
Hydraulic System Considerations
Every project begins with a detailed assessment of the functional requirements. Key considerations include:
Actuators
- Linear actuators (cylinders):
- Required force
- Stroke and speed
- Rotary actuators (hydraulic motors):
- Torque
- Speed
- Over‑run and load‑holding conditions
Power Source
- Electric (AC or DC)
- Diesel
- Petrol
- Multiple or simultaneous functions
Environmental Conditions
- Heat
- Dust
- Space constraints
- Weight limitations
- Hydraulic fluid type
System Design Elements
A well engineered hydraulic system balances performance, efficiency, and cost. Our design process considers
Pumps
- Pump type and number
- Duty cycle
- Efficiency and noise levels
Tank & Cooling
- Reservoir sizing
- Cooling requirements
- High‑efficiency layouts to reduce capital and running costs
Controls & Valving
- Manual lever controls
- Electric or electronic control systems
- Stackable valves vs. manifold systems
- Load holding functions
We frequently use manifold blocks with Sun cartridge valves to reduce:
- Weight
- Space
- Leak points
- Hose quantity
With over 5,000 cartridge options available, Sun’s range gives us enormous flexibility to tailor a system precisely to the application.
Installation Considerations
A clean, efficient installation is essential for long term reliability. We design systems to use
- The minimum number of hoses
- Fewer leak points
- Simplified routing
- Lower installation and maintenance costs
Non Hydraulic Considerations
A great hydraulic system also accounts for the environment it operates in:
- Space and mounting constraints
- Surface finish (painted, plated, stainless steel)
- Ergonomic design for operators
- Serviceability and access
Commercial Considerations
We design with the full lifecycle in mind
- Cost effectiveness
- Repeatability for future builds
- Continuity of supply (including dual‑sourcing strategies)
- Protection of intellectual property
We can also issue custom part numbers or proprietary configurations to protect OEM circuit information.
Examples of Special Projects Delivered Over 25+ Years
OEM IP‑Protected Valve Solution
We re‑issued special part numbers for Sun cartridge valves to prevent competitors from identifying circuit details. This protected the OEM’s intellectual property for a major mining client.
Integrated Motor, Valve & Gearbox Assembly
For the transport industry, we supplied a compact hydraulic motor, over‑centre valve, and gearbox assembly, followed by a redesigned DC power unit with stronger construction and thermal override. This eliminated the recurring power‑unit failures the customer had previously experienced.
60‑Tonne Mobile Test Rig
A one‑off testing system designed for simplicity, low weight, and cost efficiency. The rig incorporated dual pumps and a custom manifold to deliver reliable performance under heavy load.
Complete System Redesign Using Modular Components
We replaced an ageing system with a modular cooler, filter, and tank assembly, and engineered a single manifold incorporating all previous valve functions. The result:
- Reduced space and weight
- Fewer hoses
- Fewer leak points
- Lower overall cost
Low‑Cost, Short‑Life Special Purpose System
For a system requiring only 400 cycles, we engineered a cost‑effective solution using low‑cost components where appropriate.
Key performance requirements included:
- Four cylinders travelling within ±0.5 mm over 250 mm
- Two large rotary actuators rotating 180° and returning slowly
The critical component was a high‑precision flow divider — the only premium part required to achieve the accuracy needed.
Talk to the Experts in Hydraulic Design for your next project.
For over 25 years, we’ve delivered specialized hydraulic systems across mining, construction, transport, manufacturing, pharmaceutical, food and beyond. If you need a solution that’s engineered — not guessed — we’re here to help. Reach out today and speak with our engineering team.
