Industrial Hydraulics
The Hidden Cost of "Always On" Hydraulics—And How to Fix It
Your hydraulic pump is working hard right now. Even when your machine isn't.
If you're running fixed displacement pumps, they're delivering full flow every moment they're spinning—whether your system needs 100% capacity or 10%. It's like driving with your foot on the gas and using only the brake to control speed. It works, but it's incredibly wasteful.
The Energy Waste Problem Nobody Talks About
Here's what most plant managers don't realize: a typical fixed displacement hydraulic system wastes 30-40% of its input energy during normal operation. That energy doesn't just disappear—it becomes heat that your cooling system has to remove, creating a double cost.
Let's put numbers to it. A 50 HP hydraulic power unit running two shifts (4,000 hours/year) at $0.12/kWh costs roughly $18,000 annually to operate. If 35% of that is waste, you're literally throwing away over $6,000 per year, per machine.
Multiply that across your facility.
The Smarter Alternative
Variable displacement pumps like the Bosch Rexroth A15VSO Series 12 solve this problem elegantly: they only produce the flow your system actually needs at any given moment.
When your press is holding pressure but not moving? The pump swivels to minimal displacement, maintaining pressure with minimal flow. When you need full power for rapid advance? The pump instantly adjusts to maximum displacement. It happens automatically, hundreds of times per cycle.
The result:
- 30-40% lower energy consumption in typical industrial applications
- Reduced heat generation means smaller coolers and longer oil life
- Quieter operation when running at reduced displacement
- Extended component life due to lower thermal stress
It's Not Just About Saving Energy
Yes, the energy savings are compelling. But variable displacement brings other advantages that fixed pumps simply can't match.
- Precise Control: Need to vary press closing speed based on part thickness? Simple with proportional control. Want to sequence multiple actuators smoothly? Load-sensing makes it effortless.
- System Flexibility: One variable pump can replace multiple fixed pumps with complex valve circuits, simplifying your hydraulic schematic and reducing potential leak points.
- Modern Connectivity: With optional sensors, today's variable pumps aren't just hydraulic components—they're smart devices that report operating status, predict maintenance needs, and integrate with your machine control.
The Question Isn't "If" But "When"
The technology has matured. The energy savings are proven. The payback periods are measured in months.
The real question for manufacturers isn't whether variable displacement makes sense—it's why they're still paying to run inefficient systems.
If you're still operating fixed displacement pumps on variable load applications, you're choosing to waste money every single shift. The A15VSO Series 12 provides a straightforward path to eliminate that waste while improving machine performance.
Curious about the potential savings in your facility? A Bosch Rexroth applications specialist can evaluate your current system and calculate your expected ROI. Most manufacturers are surprised by how quickly these pumps pay for themselves.