Hydraulic power packs are the heart of many industrial & mobile systems — delivering the pressurised fluid required to power cylinders, motors, and tools. But choosing the right unit can be tricky when there are so many options available. Use the 5-step guide below to determine whether a pre-built or custom-tailored option is right for you.
Step 1: Define the Application
Before comparing technical specs, be clear about what the power pack needs to do. Consider:
- Type of equipment: it will be driving (e.g. cylinders, rescue tools, presses, winches)
- Operational environment: (workshop, mobile service vehicle, outdoors, offshore, underground)
- Duty cycle: (occasional use, frequent, or continuous)
- Speed requirements: (slow, controlled movements or rapid cycles)
Step 2: Choose the Power Source
Your operating environment largely determines whether you need AC or DC power:
- AC Power Packs– Ideal for fixed installations with mains electricity. They offer continuous operation, higher duty cycles, and minimal battery maintenance. Common in workshops, factories, and test benches.
- DC Power Packs– Designed for mobile or remote use where mains power isn’t available. Compact and portable, they run from battery sources, making them perfect for service vehicles, rescue work, and field applications.
Step 3: Select Pump Configuration
The pump type affects speed and performance:
- Single-Stage Pumps– Deliver a steady flow at constant pressure. Simpler, more affordable, and ideal for applications where speed isn’t critical.
- Double-Stage Pumps– Provide high flow at low pressure for rapid movement, then switch to low flow at high pressure for the working stroke. Best for jobs needing both speed and force, such as rescue tools and high-throughput production work.
Step 4: Determine Flow Rate & Pressure
Two key specifications dictate a power pack’s capability:
- Flow Rate (L/min): Controls how fast your equipment operates.
- Pressure (bar): Determines the force your system can apply.
Select a power pack that comfortably meets or slightly exceeds your system’s maximum requirements — overloading a pump will shorten its life.
Step 5: Consider Portability & Size
- Compact, lightweight units are easier to move and install — ideal for mobile operations.
- Larger, heavier units often provide more power and better cooling for continuous operation.
Balance portability with performance based on your working conditions.
The BOSS Hydraulics range features standard packs for the most common applications, in stock and ready to ship – or you can customise a pack to suit your needs with over 20 different circuit options available, double and single acting options and both 12/24v DC and 240/415v AC powered variants.
Need help selecting the right hydraulic power pack for your application?
Our team can provide the right advice, components, and support — no matter how tough the job so you can… let your BOSS do the hard work.
CLICK HERE to see the BOSS Hydraulics range of pre-built or custom options for Hydraulic Power Packs