How Thoughtful Choices Upfront Lead to Better Performing, More Cost-Effective Hydraulic Systems
June 10, 2026
The Hidden Costs of Oversizing Components
Must-Haves vs Nice-to-Haves in Actuator Selection
Distributors: Myth vs Reality
System Design for Pressure Intensification
The Hidden Cost of Oversizing Components
Oversizing components happens all the time in the fluid power industry. Data is often buried within long spec sheets, making it hard for system designers to know which variables really matter. One shortcut people use when they don’t have all the information is simply choosing a part that is big enough. In reality, this convenience comes with a long-term expense down the road.
Determining the right hydraulic component is a lot like buying an air conditioner for your house. Most people base it off the home’s square footage, but there are several factors that influence energy and efficiency. The Manual J calculation is the correct method for sizing your AC unit. It considers heat load, the number of windows, the direction your house faces, the home’s age, how many trees shade the property, and more. By just giving the square footage, you miss out on important variables that affect your home’s efficiency, which in return, affect your monthly energy bills.
When an AC unit is larger than it needs to be, it cools the house too quickly and shuts off before completing a full cooling cycle. This is called short cycling. Because the unit never runs long enough to operate efficiently, it uses more energy and raises electricity.
ENERGY STAR, the EPA program that certifies energy-efficient products, estimates that short cycling can reduce efficiency by as much as 17 percent. Properly sized units avoid this problem by running in longer, steadier cycles.
Oversizing components in hydraulics works the same way. If an actuator or pump is bigger than it needs to be, your system requires more oil flow and more pressure to run. If you’re using constant speed, whether the system is on or off or running at high or low speeds, you could produce much more flow than needed, which means higher running costs.
Functional vs Efficient
If a part works, there is a tendency to leave it alone. However, working and working efficiently are two very different things.
The challenge is that efficiency is invisible. A pump that’s been running for years gives you no obvious signal that it’s drawing more flow and pressure than the job requires. Component technology also keeps improving, so a part that was reasonably sized a decade ago may now be outclassed by a newer model or variable speed pumps that do the same work for less energy.
The cost of oversizing doesn’t show up all at once. It builds over the years through higher energy use, faster wear, and shorter equipment life.
While oversizing components is the easiest way to ensure your system works, it’s not the best for long-term efficiency. Getting the proper size takes more work upfront, but it can save on operating costs and avoid putting unnecessary strain on your system. Always make sure that you’re matching your components to what your system actually requires.
Must-Haves vs Nice-to-Haves in Actuator Selection
Choosing a rotary actuator does not have to mean wading through hundreds of numbers on a data sheet. In many cases, a small set of core specs and a few application details are enough to define what you actually need. Knowing which numbers are essential every time means a more simplified selection process. This guide breaks the process into three steps: main specs that size the actuator, essentials that determine functionality in your system, and the application details that come into play for non-standard jobs.
When a customer requests a quote, the first thing we ask for is torque, speed, and stroke. In most cases, these three numbers are enough to point you in the right direction:
With this information, we get a much clearer picture of the work the actuator is doing and the process it fits into. This matters most for replacements. If a unit fails in the field, these three numbers are often enough to find the right drop-in replacement.
Once the core sizing is set, the next step is confirming that the actuator can physically work and function in your system. These parameters ensure that the actuator is sized correctly, fits the machine, and won’t fail during operation.
After the essentials are covered, the final step is figuring out any application-dependent information. These details do not apply to every system, but when the applications call for them, they become just as important as the essentials above.
Selecting the right rotary actuator does not have to be complicated. Start with torque, speed, and stroke to size the unit and narrow your options, confirm the essentials that determine fit and functionality, then ensure any application dependent details your system may require.
Breaking it down this way keeps simple replacements fast and straightforward while making sure that the more demanding applications get the attention they need. When you’re not sure where a spec falls, that is exactly what our engineers are here for. Reach out to our team and we’ll help you sort the must-haves from the nice-to-haves so you get the right actuator the first time.
Learn more about our rotary actuators
Buying from a Distributor: Myth vs Reality
There are a lot of misconceptions about what a hydraulic distributor actually does. A good distributor is a technical partner that helps you specify the right components, simplify procurement, and support your application beyond the point of sale.
Why OEM Engineers Are Reconsidering System Design for Pressure Intensification
In many hydraulic systems, high pressure is only needed during short operational cycles. Even so, most OEM hydraulic power units are sized for peak load. This spike, however, may only occur occasionally. This approach comes with many downsides, including larger pumps, elevated base pressure, higher energy consumption, and added stress on components.
A hydraulic pressure intensifier offers a better path. It boosts pressure locally without raising overall system pressure. Engineers maintain a lower base pressure across the system and increase pressure only where and when it is needed. For OEM engineers focused on efficiency, compact system design, and long-term reliability, this approach may be the right solution in both new and retrofit designs.
Here are just some of the benefits that pressure intensifiers can offer: