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Power Unit Sizing Mistakes and How to Avoid Them

Power Unit Sizing Mistakes and How to Avoid Them

Sizing a hydraulic power unit (HPU) isn't just about calculating horsepower or selecting components; it's about ensuring your system performs as intended over the long haul. Whether your application involves lifting, pressing, filtering, or transferring fluid, proper sizing can mean the difference between smooth operation and chronic performance problems.

We see it all too often: systems that fall short because critical sizing factors were overlooked. Let's walk through the most common mistakes and how to avoid them.

Mistake #1: Failing to Understand the Full Application

The first and most costly mistake? Not thoroughly understanding the application. A hydraulic system's job may seem straightforward, but performance depends on more than force and flow. What exactly is the system doing? Holding pressure? Cycling rapidly? Powering multiple actuators at different intervals?

You also need to consider:
  • How much force, speed, and flow is required?
  • How often will the system run (duty cycle)?
  • Where will it be used - indoors, outdoors, in extreme climates, or at elevation?
These conditions shape everything from reservoir size to component selection. Ignoring them leads to units that are either underpowered or inefficiently oversized.

Mistake #2: Undersizing the System

Trying to save money by going smaller usually backfires. Undersized HPUs can't meet system demands consistently, which leads to:

  • Poor performance under load.
  • Increased wear and tear on components.
  • Excessive heat buildup, which then requires additional cooling
Even things like return flow rates and line lengths can create demands that many sizing calculators miss. If you miss those details, your power unit will struggle to keep up.

Mistake #3: Oversizing "Just to Be Safe"

On the flip side, oversizing a unit "just in case" introduces a new set of problems:

  • Higher upfront costs for pumps, motors, and larger reservoirs
  • Greater energy consumption and inefficient operation.
  • Space constraints in an already crowded plant floor.
Modern systems with variable-speed drives and smarter control strategies can handle fluctuating demands more efficiently than oversized fixed-displacement systems.

Mistake #4: Overlooking Environmental and Service Factors

The power unit doesn't exist in a vacuum but in your environment. Ambient temperatures, available floor space, maintenance access, and safety protocols all influence design. A well-sized unit should also be serviceable, with easy access to filters and valves, especially in high-pressure or high-duty applications.

How FSC Helps You Get It Right

At FSC, we don't just build power units; we engineer them for performance, longevity, and total cost efficiency. Whether you need a compact unit or a custom solution, we start with a deep dive into your application. We ask the right questions, assess every variable, and help you avoid the hidden pitfalls of poor sizing. 

Let's build a better system that's sized to perform and built to last.

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Your project's success is our mission! At FSC, we engineer solutions that eliminate uncertainty—so you can move forward with confidence. Our team brings deep expertise across mechanical, electrical, pneumatic, and hydraulic systems, working alongside you to design and deliver exactly what your application demands. With access to leading global brands and a no-compromise approach to quality, we’re here to make sure Nothing Can Stop You Now.