How Star Hydraulics’ Custom Solution Improved Towbar Lift System Efficiency and Reliability
In aviation ground support, efficiency and reliability are crucial not only to productivity but also to the safety of workers and passengers. Every system involved in aircraft operations must function properly, since even minor delays or failures can disrupt the tightly coordinated schedules of airlines.
A Northeastern manufacturer of ground support equipment (GSE), specializing in aircraft towbars for major U.S. and commercial airlines, faced this challenge firsthand. Their standard towbar lifting systems relied on separate hydraulic pumps, cylinders, and hoses sourced from multiple vendors. This setup led to time-consuming installations, frequent leak points, and complex procurement processes. The GSE supplier needed a simplified solution that could reduce complexity while maintaining performance and reliability.
This led them to turn to Star Hydraulics, an Alkon Corporation brand built on decades of hydraulic expertise and backed by U.S.-based engineering and manufacturing.
The Problem: Too Many Parts and Time-Consuming Installation
The GSE Manufacturer’s traditional towbar lifting system came with three major challenges. Coordinating procurement across several vendors added unnecessary complexity for the sourcing team. Installation times were long, slowing production and driving up labor costs. Finally, the use of multiple hydraulic components created more potential leak points, raising concerns about maintenance and overall reliability.
In the aviation industry, every minute matters. Even short maintenance delays can disrupt airline schedules and revenue. As noted by Omega Aviation, high-quality, dependable aircraft jacks are essential to ensuring service and repairs are completed quickly and safely, helping aircraft return to service without unnecessary downtime. 1 For this manufacturer, reducing complexity in their towbar jack systems was about more than convenience. It was about supporting airlines in keeping flights on schedule and passengers moving safely.
The Solution: An All-in-One, Custom Tow Bar Jack
When the GSE supplier turned to Star Hydraulics, they gained a partner committed to providing a comprehensive solution. Star’s U.S.-based engineering and manufacturing team worked closely with the manufacturer to gain a full understanding of the application, while also identifying key pain points and performance requirements.
Leveraging expertise from a similar existing design, Star developed a fully integrated Tow Bar Jack (TBJ) that combined the pump, cylinder, and reservoir into a single compact unit. To further meet unique needs of the GSE manufacturer, Star tailored the design by adding drain ports, modifying the breather style, and adjusting mounting points for optimal performance.
What truly set the partnership apart was the support behind the solution. When an issue arose, Star’s team provided onsite support at the airline’s maintenance department, working directly with their technicians to observe the problem and quickly deliver a fix.
The Result: Fewer Parts, Faster Installs, Lower Costs
The customized TBJ reduced installation time by nearly 50 percent. By integrating all major components into one compact unit, the GSE manufacturer was able to reduce the number of parts, hardware, and hoses required. This made installation quicker and more efficient while also minimizing potential leak points.
By reducing the number of components and the labor required for installation, this simplified design delivered greater cost savings. Furthermore, Star’s high-quality, durable TBJ helped lower maintenance costs over time by preventing frequent repairs or replacements with its corrosion-resistant components.
Hydraulic Solutions, Customized to Meet Your Needs
At Star Hydraulics, customization and collaboration are at the core of our processes and practices. By combining U.S. manufacturing, engineering expertise, and close customer partnerships, we turn proven designs into solutions that address specific needs.
Looking to reduce complexity and improve reliability in your systems? Contact your regional sales manager today to find the right solution for you.
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