Hydraulic systems vs. electric actuators: streamline your machine for greater efficiency

In the second blog of our series looking at the advantages of moving away from hydraulic actuators to electric actuators, we discuss how the characteristics of hydraulic fluid itself add a layer of complexity due to its maintenance requirements.

Some of the main concerns related to hydraulic fluid handling include:

Toxicity: The Control of Substances Hazardous to Health regulations in the UK require employers to assess and control the risks of exposure to hazardous chemicals, including hydraulic fluids, to protect workers’ health. Hydraulic fluid is known to have harmful effects such as irritation to skin and eyes or respiratory issues from inhaling fumes. In food-related applications there are also UK Food Safety Regulations that must be adhered to in order to ensure product quality and safety. 

Contamination: hydraulic fluids, particularly those that are petroleum-based, can be harmful to the environment, and UK legislation, such as the Environmental Protection Act 1990, governs the disposal of hydraulic fluids to prevent pollution. Indoor spills may require significant cleanup efforts and could be subject to local health and safety regulations.

Slips, falls and burns: leaks from system failures or maintenance activities can create slip-and-fall hazards. Some hydraulic systems reach temperatures in excess of 82°C, posing a serious burn risk to operators, as well as a fire risk when using petroleum-based hydraulic fluids.

Due to the challenging characteristics and potential toxicity of hydraulic fluids, special care is required when storing and changing the fluid. Over time, hydraulic fluid can degrade and lose effectiveness, leading to problems such as clogged filters, low oil levels, and deteriorating seals and gears, which can contribute to leaks, noise, and system malfunctions. Maintaining these systems can be costly and time-consuming, requiring regular fluid changes, inventory management, and disposal procedures to avoid spills. Failing to manage these maintenance tasks can lead to reduced machine reliability, unexpected downtime, and greater environmental impact.

In contrast, electromechanical actuators offer a much cleaner alternative, utilising electrical energy instead of hydraulic fluids. They typically require minimal lubrication, and many models feature self-lubricating components, eliminating the need for frequent fluid changes and reducing the overall maintenance burden.

Electromechanical systems not only simplify machine design but also help mitigate many of the risks associated with hydraulic systems.  If you often specify hydraulic systems in your designs, get in touch with us to discover how switching to an electromechanical solution can enhance your machinery.  In collaboration with our trusted partner, Thomson Industries Inc. we offer cutting edge electric linear actuators that deliver efficient performance.  Explore our full range here.