Bespoke Hydraulic Power Packs
Monitoring fluid condition and viscosity to ensure consistent system performance, reduce wear, and support accurate testing and validation.
Bespoke Hydraulic Power Packs
Curtis Assemble & Test Ltd (CAT) design and manufacture bespoke hydraulic power packs (also commonly referred to as Hydraulic Power Units (HPUs) or hydraulic conditioning systems depending on application) engineered for demanding production, test, and conditioning applications. Developed from decades of experience in high-pressure hydraulic systems, our power packs deliver stable flow, precise pressure control, and reliable temperature conditioning across a wide range of industrial environments.
Systems are available as both mobile and fixed installations, supporting test bench operation, external equipment supply, and specialised conditioning tasks. Filtration, monitoring, and safety functions are integrated as standard, ensuring consistent oil quality and long-term component protection.
By combining robust hydraulic design with application-specific control strategies, CAT systems help improve operational performance, reduce downtime, and meet stringent quality requirements in modern manufacturing.
FLEXIBLE SYSTEM DESIGN FOR MOBILE OR FIXED INSTALLATIONS
CAT hydraulic power packs can be engineered as mobile wheeled units or fixed installation systems depending on production layout and performance requirements. Mobile configurations are suited to multi-station support, field testing, and flexible R&D environments, while fixed systems provide dedicated supply for continuous industrial operation.
Multi-circuit configurations allow separate test fluid and lubrication oil supplies to operate simultaneously, each with independently controlled flow, pressure, and filtration performance.
For mobile power pack applications, the test circuit can deliver flow rates up to 50 l/min through a 3-micron filter, while the lubrication circuit can supply up to 60 l/min through a 10-micron filter.
For fixed installation power packs, the test circuit can provide 41 l/min at pressures up to 180 bar through a 10-micron filter, while the lubrication circuit can deliver 116 l/min at pressures up to 275 bar through a 30-micron filter.
Additional conditioning features such as heating, cooling, and viscosity monitoring can also be incorporated to ensure consistent test media quality and reliable system performance.
Each system is engineered to suit the application, with configurable reservoir capacity, operating parameters, and control features to support long-term reliability and efficient hydraulic operation.
TEMPERATURE, FLOW & FILTRATION CONTROL
Precision control of hydraulic oil is essential for both testing and production environments. CAT power packs offer integrated heating, cooling, and filtration systems to ensure stable test conditions and safeguard downstream equipment.
Dual 3kW in-line heaters in temperature conditioning modules can deliver tightly controlled oil temperatures from ambient up to 160°C, supporting both performance testing and oil viscosity manipulation. Optional coolant connection allows temperature control between 15°C – 160°C Filtration stages remove particulate contamination down to 3 Microns (typical), while reservoir monitoring, bunding, and safety instrumentation protect against dry run, overflow, and operational hazards.
With options for servo-controlled flow, proportional pressure control, multi-line distribution, and real-time monitoring, CAT hydraulic power packs deliver a dependable supply infrastructure for specialist machinery, test rigs, and industrial automation.
HYDRAULIC POWER PACK SYSTEM CAPABILITIES
⚙️ Flow range: 10 to 100 L/min, supporting both lubrication and high-demand test circuits
⚙️ Pressure range: 1 to 300 bar for a wide range of hydraulic equipment and component requirements
⚙️ Temperature conditioning: Ambient up to 160°C, enabling viscosity control and performance evaluation
⚙️ Filtration performance: Multi-stage filtration ranging from 3 to 25 microns (typical), ensuring clean, reliable oil supply
⚙️ Power capability: Up to 60 kW installed motor power depending on system architecture
⚙️ Circuit configurations: Dual-circuit systems for independent test fluid and lubrication supply
⚙️ Media conditioning: Heating, cooling, and viscosity management options for stable oil characteristics
⚙️ Control options: Servo-controlled flow and pressure, proportional valves, and closed-loop monitoring
⚙️ Installation types: Available as mobile wheeled units or permanent fixed installations
⚙️ Safety & environmental features: Reservoir bunding, level monitoring, and contamination protection systems
Each CAT hydraulic power pack is engineered to deliver stable and repeatable performance, ensuring consistent oil quality and supporting reliable operation of specialist test rigs, automated machinery, and external equipment. These hydraulic power pack systems are used across aerospace, automotive, robotics, test rig, and advanced manufacturing environments where precision control of temperature, pressure, and cleanliness is critical.
COMMON APPLICATIONS
CAT hydraulic power packs support a diverse range of test, conditioning, and operational environments where stable hydraulic performance is critical. From prototype validation through to end-of-line production, each system can be configured to meet your process, performance, and safety requirements. Typical applications include:
Test Rig Hydraulic Supply
Provides a stable hydraulic supply for component and system test rigs, supporting controlled flow, pressure, and temperature conditions during development and validation testing.
Oil Conditioning & Temperature Control
Hydraulic power packs used for oil temperature conditioning, viscosity control, and media stability to support consistent test and production environments.
Dual-Circuit Test & Lubrication Systems
Dual-circuit configurations supply separate test fluid and lubrication oil simultaneously, enabling flexible production and testing operations.
Mobile Hydraulic Power Support
Mobile hydraulic power packs designed for multi-station support, flexible R&D environments, or temporary test setups where mobility is essential.
Fixed Installation Hydraulic Supply
Fixed installation systems provide continuous hydraulic power for permanent machinery, specialist equipment, and industrial production environments.
Multi-Line Distribution & Clamping Systems
Multi-line hydraulic systems supplying multiple clamps, actuators, or tooling circuits with configurable valve islands and flow/pressure control.
Industries We Support
- Automotive Manufacturing – hydraulic power for assembly machines, clamping systems, and endurance test equipment.
- Industrial Automation – powering bespoke machinery, presses, lifts, and multi-axis automation systems.
- Aerospace – reliable hydraulic supply for precision tooling, fixtures, and safety-critical manufacturing processes.
- Defence & Heavy Engineering – robust hydraulic units for demanding environments where durability and consistent performance are essential.
Example Engineered Power Pack Solutions
Special Purpose Conditioning Unit
⚙️ Dual circuits supplying test fluid at independently controlled operating conditions
⚙️ Individually adjustable fluid temperatures from 15°C to 160°C
⚙️ Flow rates up to 100 L/min at pressures up to 10 bar
⚙️ High-efficiency 3-micron filtration for guaranteed fluid cleanliness
⚙️ Engineered for consistent performance in temperature-critical and contamination-sensitive environments
Multipurpose Power Pack
⚙️ Four supply lines delivering:
∘ 2 × 7 L/min at 300 bar
∘ 2 × 60 L/min at 100 bar
⚙️ Four oil supply and four return lines fitted with 25-micron and 6-micron filtration
⚙️ Two fully independent clamp circuits with configurable valve islands for varied clamping requirements
⚙️ Reservoir fitted with warning and abort level switches to protect pumps from dry running
⚙️ Standard fluid temperature monitoring with optional closed-loop temperature control
⚙️ Electronic flow meters on each supply line for precise flow monitoring
⚙️ Integrated bund designed to contain full fluid volume in the event of spillage
WHAT WE CAN DELIVER
Bespoke hydraulic power packs tailored to your application and environment
Mobile or fixed installation systems for flexible or permanent operation
Dual-circuit configurations for simultaneous test fluid and lubrication supply
Integrated temperature conditioning for controlled viscosity and oil performance
Multi-stage filtration for clean and reliable hydraulic media supply
Servo-controlled flow and pressure for precise system operation
Multi-line distribution for clamps, tooling, and external equipment
Full PLC, HMI, and software control with real-time monitoring
Safety and environmental features including bunding and reservoir protection
In-house design, build, commissioning, and validation compliant with CE/UKCA
Looking for a bespoke hydraulic power pack solution?
Our engineers will help define the right system for your flow, pressure, temperature, and installation requirements.
Talk to our engineering team, we’ll help define the right hydraulic power pack for your application.
Why Choose CAT?
☑️ Bespoke System Design
Each power pack is engineered around your flow, pressure, temperature, and installation requirements.
☑️ Multi-Circuit Capability
Dual and multi-line configurations support simultaneous test fluid, lubrication, clamping, and tooling operations.
☑️ Precise Conditioning & Control
Integrated heating, cooling, filtration, and servo control deliver stable hydraulic performance in demanding environments.
☑️ Mobile or Fixed Installation
Systems can be configured for flexible multi-station support or continuous industrial operation.
☑️ Safety & Compliance Built In
Filtration, bunding, monitoring, and instrumentation protect operators, equipment, and oil quality.
☑️ Trusted Engineering Partner
Decades of experience supplying hydraulic solutions for specialist test rigs, automation, and production equipment.
Real-World Performance, Real-World Trust
Looking for a trusted partner to deliver your hydraulic power pack system?
Our engineers will design and manufacture a bespoke solution tailored to your performance, conditioning, and installation requirements.