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Running Your Hydraulic Systems For LESS

Rob Panzarella
Posted by Rob Panzarella on Jul 7, 2022 1:27:00 PM


It feels like everyone is looking to reduce emissions and consumption these days - all while still maximizing output, of course, and industrial hydraulics is no different. It's easy enough to say, "we need to be more efficient," but the problems show up when it comes down to actually reducing and maximizing a system, leaving industrial customers wondering, "How do I run a hydraulic system for less?"

Airline partnered with engineers at Bosch Rexroth, who have been innovating the answer to this question for years, to bring their knowledge straight to you. Let's dive into how you can get more out of your hydraulic system using significantly less energy, downtime, noise, oil, and ultimately, less money. 

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Less Energy | Application Example Video | Less Carbon Footprint

Less Noise | Less Oil | Summary & Resources


Less Energy & Downtime 

Efficient Gears

The secret to getting more with less is efficiency, but unfortunately, traditional hydraulic systems were NOT designed with efficiency in mind. Most applications use fixed-speed electric motors and/or a fixed displacement pump. This leads to a significant energy offset, because the motor runs at full speed for the majority of the operation, even when unnecessary. 20-80% of the average power consumed by a machine using fixed-speed hydraulic pumps is wasted energy. What happens to all the unused energy? It gets converted to heat, requiring even more power to cool it! Running a system at max speed consistently also makes parts wear faster, causing pumps to wear faster.

The solution lies with Variable Speed Pump Drives, which only deliver maximum flow power when you're using it, enabling massive energy, heat, and system wear savings. Watch this minute-long video below for a short application example:



Watch the in-depth, 25-minute webinar with application breakdowns for each "less" here anytime, or keep reading for a short overview!

Watch our Full On-Demand Webinar


Less Carbon Footprint

Carbon FootprintOne of the most impressive benefits of switching to a more efficient system is reducing your organization's carbon footprint (the amount of greenhouse gas emissions a person or organization emits). Lowering an organization's carbon footprint is beneficial for many different reasons. First and foremost, it helps mitigate the effects of global climate change, improves public health, and improves company morale.   Significant financial benefits also help make the switch to energy-efficient pumps worthwhile, as organizations that actively reduce their carbon emissions are often eligible for rewards or subsidies from the government and energy companies. These are often in the form of favorable tax treatment, grants, and low-interest loans.


Less Noise 

Hydraulic systems are LOUD, but they don't always have to be! The noise from a hydraulic system comes from the rotational energy put into the motor, the coupling connecting the motor to the pump, the pump internals rotating, and the pressure pulsation noise. By reducing the rotational speed while the system isn't in use with a Sytronix system, like the DRN Control Drive, you can significantly reduce the noise of the system, often by over 10 decibels! Lowering noise levels drastically improves any industrial work environment noticeably, but don't just take my word for it, listen for yourself!



Less Oil

oil-6915740_1920The rule of thumb to size a hydraulic oil reservoir says it should be a minimum of 3 to 5 times the maximum pump flow, so that the oil can properly degas (the air bubbles all rise to the surface). That puts a 40 GPM hydraulic pump at needing a 120 to 200-gallon reservoir. Optimizing the flow path of the oil degassing can reduce the necessary oil volume by four times, thus, dropping the necessary oil of a conventional 160-gallon reservoir down to only needing 40 gallons of oil. The material cost savings alone is massive, but this also helps reduce your carbon footprint as well!



The energy-saving hydraulic design techniques of Sytronix maximize the efficiency of your system to do more with SO much less! Create long-term improvements in your system's efficiency, longevity, and cost of ownership. Of course, that's in addition to reducing your systems' noise output and carbon footprint!


2022-07-06 19_29_37-How to Run Your Hydraulics for Less _ On-Demand Webinar Recording - YouTube


For deeper explanations and application examples, watch the full How to Run your Hydraulics for Less webinar here anytime -


Watch our Full On-Demand Webinar


We're Here for Hydraulic Support

At Airline, building hydraulic power units is one of our specialties. We have over 65 years of experience building and servicing hydraulic power units. Even better, we have the capabilities to complete the entire project, including consultation, engineering, manufacturing, installation, field service, and training. Don't hesitate to use us as a resource!

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Topics: Hydraulics, Explainers

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