Standard units are preconfigured for common applications, while custom hydraulic power units are engineered to meet specific performance, space, duty-cycle, and environmental requirements.

With proper maintenance, a hydraulic power unit can last 10–20 years or more. Longevity depends on operating conditions, usage, and service intervals.

Electric HPUs are typically used indoors and offer quieter operation, while diesel-powered units are better suited for mobile or remote applications where electricity is not available.

To size a hydraulic power unit (HPU), you must work backward from your actuator’s load requirements to define three core specifications: pressure, flow rate, and motor power.

First, determine the operating pressure (PSI) by dividing the required force by the actuator’s effective area, typically choosing a unit that operates at 70–85% of its maximum rating for longevity.

Next, calculate the flow rate (GPM) based on the actuator volume and the desired cycle speed. With flow and pressure determined, the motor horsepower can be calculated.

Hydraulic pumps create heat. The duty cycle is critical because it directly dictates the heat generation and mechanical wear the hydraulic power unit must endure over time. Since no system is 100% efficient, energy lost during operation is converted into heat; a unit running continuously (100% duty cycle) will reach much higher temperatures than one operating intermittently. The addition of a properly sized heat exchanger will prevent fluid degradation and seal failure.