Green Hydraulic Power Deploys VFD-Based Hydraulic Systems to Cut Energy Use

Hydraulic systems are widely used in manufacturing for press operations, forming, molding and other high-force applications. However, conventional hydraulic power units typically operate continuously at fixed motor speeds, even during production dwell times. This operating model leads to significant energy losses.

Green Hydraulic Power (GHP), founded in the United States, has developed hydraulic systems designed to improve energy efficiency by integrating variable frequency drives (VFDs) into pump control architectures.

Addressing Idle Energy Consumption
In many production environments, hydraulic equipment experiences frequent idle periods when no motion or pressure demand is present. Traditional systems maintain constant motor speed to ensure immediate response, consuming energy even when flow and pressure are not required.

GHP’s systems use Rockwell Automation Allen-Bradley PowerFlex 755 VFDs to dynamically adjust motor speed according to real-time demand. By reducing pump speed during low-load or idle conditions, the system minimizes unnecessary energy consumption.

According to GHP, this approach can reduce energy usage by up to 80% compared to conventional fixed-speed hydraulic systems, depending on duty cycle and application.

Reduced Heat Generation and Cooling Demand
Fixed-speed hydraulic systems often generate excess heat due to continuous operation and throttling losses. This heat must be dissipated through oil coolers or cooling towers, increasing overall facility energy demand.

By matching pump output to process requirements, VFD-controlled systems reduce internal heat generation. Lower thermal loads can reduce or eliminate the need for energy-intensive cooling infrastructure. In some installations, customers have removed cooling towers after implementing the VFD-based hydraulic solution.

Noise Reduction and Workplace Safety
Hydraulic power units operating at constant high speeds can produce elevated noise levels. GHP reports that its VFD-controlled systems reduce noise by approximately 20 decibels compared to conventional units.

Lower acoustic emissions improve workplace conditions and can contribute to occupational safety compliance by reducing exposure to high sound levels.

Operational Sustainability in Manufacturing
Electric motors in hydraulic systems account for a significant share of industrial energy consumption. By integrating variable frequency drive technology into hydraulic power units, GHP aims to align hydraulic performance with actual production demand.

The combination of energy savings, reduced cooling requirements and lower noise output positions VFD-driven hydraulic systems as an alternative to traditional constant-speed architectures in manufacturing sectors seeking improved operational efficiency and sustainability.