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Custom Pneumatic and Hydraulic Actuators – How are Speciality Actuators Made?

Custom Pneumatic and Hydraulic Actuators - How are Speciality Actuators Made?

Custom pneumatic and hydraulic cylinders are solutions created for the most demanding industrial processes, where standard models do not always meet the needs of the application. Their main advantage is the ability to precisely adjust parameters – such as stroke range, type of seals or additional equipment (e.g. position sensors) – to specific operating conditions. As a result, these devices are suitable for use in industries such as mining, for example, as well as in the manufacture of packaging machines for bulk materials (cement, gypsum, adhesives).

In this article, we will introduce you to the process of designing and manufacturing special actuators at CPP PREMA, which has been providing customers with innovative personalised solutions for more than 40 years. You will learn what to look for when you need a custom actuator – from consulting an engineer, through material selection and prototype testing to final implementation into the production line. We’ll also showcase example implementations, including actuators with adjustable stroke and models integrated with a travel transducer for use in harsh mine environments. We encourage you to read on to learn all the benefits of investing in bespoke equipment for your business.

What makes custom actuators stand out?

Custom actuators, also known as special actuators, are devices designed and manufactured for the specific requirements of an application. Unlike catalogue solutions, they can be customised in almost every aspect – from dimensions and type of seals to advanced measurement systems or specialised coatings. As a result, they operate reliably even under extreme conditions (e.g. mines, bulk material packaging lines, flotation machines).

In addition, customised actuators are an excellent alternative to multi-stage equipment, where the operating range is predetermined and there is no freedom of adjustment. In what follows, we have a closer look at the three key features that distinguish this type of solution.

Regulacja skoku – pełna elastyczność w procesie produkcyjnym

One of the biggest advantages of custom actuators is the optional stroke adjustment, allowing the length of piston rod extension to be adapted to the current needs of the process.

  • Example:
    Actuator 18.3127 D63x60/45 with manual stroke adjustment – used in packaging lines for bulk materials (e.g. lime, gypsum, cement).
    Thanks to the durable micrometer graduation, extremely precise control of the stroke is possible in the range of 0-XXX mm (value individually set by the designer).
  • Advantages:
  1. Rapid changeover of the line without having to replace the entire actuator.
  2. Minimised costs and production downtime.
  3. Greater compactness and lower cost compared to multi-stroke actuators, which generally take up more space and do not allow for free adjustment.

Tip: The use of adjustable-stroke actuators can significantly reduce the time it takes to change the assortment in packaging equipment, resulting in higher efficiency of the entire line.

Position sensors - precision at the highest level

In many industries, it is crucial to accurately control the position of the piston rod and control its operation in real time. Actuators integrated with sensors or path transducers allow for real-time monitoring and adjustment of movement, increasing precision and process safety.

  • Example:
    Actuator 18.4516 D125x100 BSPT with BTL linear path transducer – used in flotation machines in mines or ore benefaction plants.
    The BTL sensor enables precise readings of the piston rod position, which makes it easier to monitor the entire process and react quickly to any deviations.
  • Advantages:
    Greater accuracy – infinitely adjustable piston stroke to the millimetre.
    Possibility of remote process monitoring and control.

Reduced risk of failure due to early detection of abnormalities.

Special coatings and seals - resistance to harsh conditions

Another distinguishing feature of custom actuators is the use of advanced anti-corrosion coatings and special sealing materials. This is of great importance in areas with high levels of dust, humidity or in situations where the actuators are exposed to corrosive substances.

  • Example:
    Actuator 18.4647 D200x300 with C5-M coating and VITON seals – operated in a mine for controlling flaps.
    The special coating protects the surface of the actuator against corrosion, while the VITON seals guarantee high resistance to temperatures and aggressive media.
  • Advantages:
    Long service life and infrequent maintenance downtime.
    Reduced operating costs thanks to robust materials.
    Safe operation in areas exposed to extreme conditions.

Tip: When selecting a special actuator for dusty conditions or contact with chemicals, ensure that the manufacturer offers dedicated coatings and seals.

With these features, custom actuators significantly outperform standard solutions in demanding applications. This translates into increased productivity, reduced service costs and the ability to quickly adapt machines to new tasks.

If you are looking for customised pneumatic or hydraulic actuator solutions, it is essential to consider the selection of customised equipment – especially if the operating conditions of your production line are outside the typical performance range provided by the manufacturers of standard models.

Custom actuator design and manufacturing process

Manufacturing special actuators requires close collaboration between the engineering team and the customer. Only then is it possible to fully understand the needs of the end user and develop a device that not only meets, but often exceeds, expectations. The main steps in this process are outlined below.

Analysis of the customer's needs

The first step is to identify the technical requirements and operating conditions in which the actuator will operate. The engineers at CPP PREMA take into account:

  • Temperature and humidity range.
  • The type of medium (air, hydraulic oil, special fluids).
  • Operating loads and pressures.
  • Mounting space and installation possibilities (e.g. unit size restrictions).
  • Standards and certifications required by the industry (e.g. ATEX, ISO).

Based on this information, a technical specification is produced, which becomes the starting point for further design work.

Tip: The more details the customer provides at this stage (e.g. technical drawings, environmental conditions, operational requirements), the more precisely a solution can be selected.

Concept and design development

The next step is to prepare the actuator concept and preliminary technical drawings. With this:

  1. The choice of design solutions is consulted, e.g. type of seals, type of actuator, or possible accessories (sensors, travel transducers, additional scraper or piston rod guard).
  2. A detailed CAD design is produced, including dimensions, materials and manufacturing technology.
  3. Once the customer (or his technical department) has approved the documentation, the prototyping phase begins.

Selection of materials and components

In custom actuators, the quality and durability of the materials used are crucial. Depending on the application and industry, engineers can suggest:

  • Stainless or alloy steel with improved wear resistance.
  • Anti-corrosion coatings (e.g. C5-M) for marine, mining or highly dusty environments.
  • VITON, EPDM or other seals dedicated to high temperatures and aggressive substances.
  • Electronic components (position sensors, distance transducers) in applications requiring precise monitoring of the piston rod movement.

This ensures that the final product is resistant to operating conditions, resulting in a longer service life and lower operating costs.

Prototype testing and implementation

Once the first prototype has been created, the actuator undergoes a series of tests:

  1. Pressure tests – check for tightness and resistance to maximum loads.
  2. Motion simulations – reflect typical operating cycles in a real application.
  3. Compatibility tests with control systems and associated equipment (e.g. inverters, PLCs).

If the tests are successful, the actuator can be implemented in the production line. If necessary, adjustments are made to the design to further adapt the device to the specific requirements of the process.

Quality control and after sales support

At the end of the manufacturing process, each custom actuator is subjected to a final quality check, whereby:

  • Documentation compliance and critical dimensions are verified.
  • The operation of the stroke control mechanisms or sensors, if used, is checked.
  • The technical documentation and certificates required for the industry (e.g. ATEX certificate) are provided to the customer.

Furthermore, CPP PREMA provides after-sales support, including technical advice, warranty and post-warranty service and spare parts availability. Thus, users of special actuators can count on fast and professional assistance in the event of upgrades or extensions to the equipment.

Tip: To ensure the maximum service life of the actuator, it is advisable to follow the manufacturer’s maintenance recommendations, such as regular lubrication of the guides and inspection of the seals.

In summary, the process of designing and manufacturing custom actuators combines a detailed need’s analysis, precise material selection, meticulous testing and comprehensive support. Only this approach guarantees that the final product will stand up to even the most demanding operating conditions, ensuring high performance, safety and reliability in daily operation.

Examples of projects

Below are several custom actuators designed and manufactured at CPP PREMA. Each has been tailored to the specific requirements of a particular industry and machine, allowing for significant improvements in industrial processes.

Actuator D63×60/45 with stroke adjustment - bulk material packaging lines

  • Application: Packaging machine in the construction industry (production of gypsum, adhesives, cement).
  • Description of the solution:
    Stroke adjustment in the range 0-XXX mm (value set individually by the constructor).
    Durable micrometer graduation, facilitating precise change of piston stroke settings.
    Quick changeover of the line without having to replace the entire actuator.
  • Benefits:
    Ability to handle different types of bags and bulk materials at one station.
    Reduced downtime due to seamless adaptation to changing production needs.

Actuator D63×60/45

  • Application: Automatic gypsum bagging line (also construction industry).
  • Solution description:
    Modelled on another manufacturer’s design, adapted to customer requirements.
    Manual stroke adjustment in a similar range to 4.1.
    Reinforced cylinder design, suitable for intensive dusty environment.
  • Benefits:
    Retention of proven solutions from a renowned manufacturer.
    Increased wear resistance due to robust design and selected materials.

Actuator D125×100 BSPT with BTL linear encoder path

  • Application: Flotation machine in a mine, ore benefaction process.

  • Solution description:
    Built-in BTL path transducer, guaranteeing precise measurement and control of the piston rod position.
    Design suitable for high humidity and exposure to intensive dust and slurries.
    Robust seals to ensure sealing under high loads.

  • Benefits:
    Increased accuracy of the flotation process – every change in piston position is continuously monitored.

    Minimised risk of failure, resulting in increased productivity and operational safety.

Actuator D200×300 with C5-M coating and VITON seals

  • Application: Control of flaps in a mine.
  • Solution description:
    Specialised C5-M coating to protect the cylinder against corrosion in high humidity and aggressive environments.
    VITON seals, resistant to elevated temperatures and chemicals.
    Construction designed to operate in extremely dusty mine environments.
  • Benefits:
    Long service life and reduced maintenance costs.
    Safe and stable operation in harsh environments, reducing the risk of downtime.

Each of the solutions described confirms that special design actuators not only increase the flexibility of production lines, but also reduce operating costs. Well-chosen materials, clever designs and precise measurement systems make them suitable for a wide range of industries – from bulk material packaging and ore benefaction to the control of dampers in mines.

If you are looking for tailor-made solutions that can cope with unusual conditions, contact our technical department at CPP PREMA. We will be happy to advise and suggest an actuator tailored exactly to the requirements of your application.

Main benefits of customised actuators

Choosing special actuators over standard solutions is a step that makes a real difference in streamlining processes and making your company more competitive. Here are the key advantages you gain by opting for made solutions.

Precise adaptation to process requirements

  • Customised parameters – customised actuators are created based on a thorough analysis of the operating conditions, allowing perfect adaptation of dimensions, stroke range or type of seals.

  • High accuracy – especially in applications where every millimetre matters (e.g. packaging lines for bulk materials or flotation processes).

    Tip: Thanks to the precise stroke adjustment, the production line can be easily rearmed, saving time and money.

Durability and reliability under difficult conditions

  • Special materials and coatings (e.g. C5-M, stainless steel, VITON seals) allow the actuators to operate efficiently even under extreme conditions (high humidity, high temperatures, aggressive media).

  • Reduced risk of failure – longer operating time without the need for component replacement or repair, which has a positive effect on OEE (Overall Equipment Effectiveness) indicators.

    Example: Actuators used in mines are not subject to rapid wear thanks to reinforced seals and anti-corrosion coatings.

Faster changeovers and greater production flexibility

  • Easy change of operating parameters – made possible by adjusting the stroke or using position sensors to ensure constant control of the piston rod movement.
  • Ability to operate different products on the same line, without incurring the cost of purchasing new actuators.

Savings in the long term

  • Lower downtime costs – longer service life and infrequent failures reduce unplanned production interruptions.
  • Reduced maintenance expenditure – dedicated seals and coatings protect the actuator from premature wear, reducing service expenditure.
  • Better utilisation of resources – one universal adjustable stroke actuator often replaces several units with different specifications.

Support for innovation and development

  • Expandable with new functions and sensors (e.g. BTL path transducers, real-time monitoring systems).

  • Adaptation to industry standards – including ATEX, ISO or environmental requirements.

    Market competitiveness – automation with customised actuators allows faster response to changes in demand and adaptation of offerings to customer needs.

When you opt for special design actuators from CPP PREMA, you gain a versatile tool that not only increases production efficiency, but also enhances the quality, safety and profitability of your processes. This enables your company to grow more dynamically, offering more diverse products and services – all with optimum maintenance costs and attention to the high durability and reliability of the equipment.

How do you choose the right special actuator manufacturer?

Choosing a proven manufacturer of customised actuators is key to achieving high quality and reliability in industrial processes. Here are the most important factors to consider before deciding on a partnership.

Experience and sector specialisation

  • References and portfolio – check whether the manufacturer has a track record in a similar industry (e.g. mining, construction or packaging).

  • Many years of practical know-how – companies with longer experience usually have proven design and manufacturing procedures, which translates into shorter lead times and less risk of errors.

    Tip: Ask for examples of specific projects. If the manufacturer can point to equipment that works in conditions similar to yours, it’s a sign that it has the necessary competence.

Fully customisable

  • Design flexibility – make sure the manufacturer offers turnkey solutions, i.e. taking into account all your technical requirements (e.g. type of coatings, special seals, stroke range).

  • Fit with standards and certifications – for applications requiring, for example, ATEX compliance, it is important that the manufacturer has experience of working with such regulations.

    Example: CPP PREMA carries out customised projects, taking into account requirements such as those for explosive environments (ATEX) or industries with high hygiene standards.

Technical and engineering facilities

  • Modern software – the manufacturer should use advanced design tools to speed up and facilitate documentation.

  • In-house laboratory and test benches – these enable the company to carry out strength tests, pressure tests or simulations of equipment operation under near real-world conditions.

    Find out more: enquiry about the details of the test processes – whether they include, for example, leak testing, verification of corrosion resistance or checking the accuracy of road transducers.

 

Comprehensive service and after-sales support

  • Warranty and post-warranty service – does the manufacturer offer fast service response, technical support and spare parts availability?

  • Technical advice – a good company will help to optimise parameters, implement any modifications after testing and offer assistance in integrating actuators into existing systems.

    Tip: Determine whether the manufacturer provides maintenance manuals, installation diagrams and other important technical documents – this makes it significantly easier to operate the actuator on a day-to-day basis.

Transparent quality policy

  • Certifications (e.g. ISO 9001) – confirm the maintenance of specific standards in quality management and manufacturing processes.
    ATEX , KOMAG

  • Rigorous inspection procedures – quality-minded manufacturers carry out detailed tests at every stage of production, which reduces manufacturing defects and translates into equipment reliability.

    Tip: Ask for documentation confirming manufacturing quality – e.g. material approvals, leak test reports or load test reports.

The choice of the right special actuator manufacturer should be well considered, as it affects the continuity of production, its efficiency and the safety of personnel. Carefully analyse the competences and offerings of your potential supplier, paying attention to experience, flexibility and approach to quality.
This will provide you with a partner who can meet the requirements of your industry and offer sustainable, innovative solutions that meet the real needs of your plant.

Summary

Choosing custom pneumatic and hydraulic actuators is an investment in solutions that will not only increase process efficiency, but also improve process safety and flexibility. Thanks to the personalized parameters of carefully selected materials and advanced measurement systems (e.g., BTL path transducers), such actuators are used even in the most demanding applications – from bulk material packaging and the mining industry to the control of flaps or flotation machines.

In the article, we discussed key aspects related to the design and manufacturing process of special actuators, presented sample implementations and highlighted the main benefits of implementing such solutions. We also pointed out how the right choice of manufacturer can determine the success of the entire project – what matters is industry experience, technical background, comprehensive service and quality confirmed by certificates.

If you are looking for personalized, durable and reliable pneumatic or hydraulic cylinders, we invite you to contact our experts at CPP PREMA. We will be happy to help you tailor a device to the specific requirements of your industry, so that your production processes become as efficient and downtime-resistant as possible. This will give you a competitive edge and keep your process lines running stably and efficiently for many years to come.