Where intensifiers are used

hydraulic intensifier

The most common solution for achieving high pressure is to build a power pack or HPU, in which the pump generates the required high pressure. The entire system must be designed for high pressure in this solution. As an alternative, you can add an intensifier to an existing or new system designed for lower pressure 

It is important to remember that when using intensifiers, the full pump flow will initially be supplied to the high pressure side, for example, to move a cylinder rod into position. When the pump pressure is reached, the intensifier automatically kicks in and raises the pressure in the cylinder to the required higher pressure.

When operating a clamping cylinder, for example, the intensifier is typically positioned between a directional valve and the cylinder. Connecting the intensifier’s P-port to the pump and the T-port to the tank allows the full pump flow to pass through the intensifier’s integrated check valves, causing the cylinder to move into position pump speed.

When the cylinder is in place and pump pressure is established inside the  hydraulic intensifier automatically raises the pressure to the required end pressure. Because the cylinder is now filled with oil, the pressure rises quickly, usually within a few seconds. In this case, the intensifier will maintain the pressure automatically.

To revert the cylinder rod, activate the directional valve on the pump side, which connects pump pressure to the intensifier T-port and the P-port to the tank. This causes a pilot signal to be sent to an integrated pilot-operated check valve (dump valve or POV), which opens and creates a direct path from the cylinder to the intensifier and back to the tank. Intensifiers can be used with any type of fluid.

Specifying hydraulic pressure intensifiers

  1. When specifying a hydraulic pressure intensifier, four parameters must be taken into account:
  2. What is the actual output pressure that is required in psi?
  3. What is the inlet flow measured in gpm?
  4. What is the supply situation?
  5. How will the intensifier solution be installed (flange, brackets, pipe clamp, etc.)

Why should you use an intensifier


  • There is a low operating pressure in the system
  • Power source should be used that is already installed
  • Tubes, hoses, and valves should be standard
  • Easily accommodated wherever needed
  • There is no need for extra tubing or special parts
  • At pump pressure, full flow is available
  • For the new task, use existing equipment


  • Where pressure is needed, it is higher
  • Low pressure power source produces higher pressure
  • Intensifier supplied with low pressure
  • Compact solutions are available with intensifiers
  • Cylinder-mounted intensifier
  • Bypass valve and POV built-in


  • System-wide energy savings
  • There is no need for expensive horsepower components
  • A lower total cost and a higher level of safety
  • Installation saves money
  • By installing, you can save money and space
  • Operation until high pressure is reached in a short amount of time

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