Date: 03-06-2026
Project Details
Power Pack Model: AC Hyd Power Pack-CDA-3P-1HP-IE4-2STN-Q3534
This study was conducted to compare the performance of two hydraulic gear pumps having the same displacement (3.2 cc/rev) operating with the same motor and test setup.
Test Setup
Motor Used:
AC Motor – 3 Phase
1 HP
1440 RPM
Face Mount
415V, 50Hz
IE4 Efficiency Class
Make: Hindustan Motors
Test 1 – China Gear Pump
Pump Model: Gear Pump-3.2CC/Rev-GP-F203.2
Test Results
Flow: 5.0 LPM
Pressure: 70 Bar
Motor Current: 1.6 A
Motor: 1 HP IE4
Observation
The pump delivered 5.0 LPM at 70 Bar while drawing the motor's full load current of 1.6 A.
Test 2 – Marzocchi Italy Gear Pump
Pump Model: EK1P-S-5-G (3.2 cc/rev)
Test Results
Flow: 5.5 LPM
Pressure: 90 Bar
Motor Current: 1.6 A
Motor: 1 HP IE4
Observation
The Marzocchi pump delivered 5.5 LPM at 90 Bar while drawing the same current of 1.6 A.
Performance Comparison
Parameter | China Pump | Marzocchi Pump | Improvement
Flow | 5.0 LPM | 5.5 LPM | +10%
Pressure | 70 Bar | 90 Bar | +28.6%
Current Drawn | 1.6 A | 1.6 A | No Increase
Motor Rating | 1 HP | 1 HP | Same
Key Findings
The Marzocchi pump produced approximately 10% higher flow than the China Hydraulic pump.
The Marzocchi pump achieved approximately 28.6% higher pressure than the China Hydraulic pump.
Both pumps operated with the same motor and drew the same current (1.6 A).
The results indicate superior volumetric and mechanical efficiency of the Marzocchi gear pump.
Hydraulic Power Comparison
Hydraulic Power (kW) = (Pressure × Flow) / 600
China Hydraulic Gear Pump
Hydraulic Power = (70 × 5.0) / 600
= 0.583 kW
Marzocchi Pump
Hydraulic Power = (90 × 5.5) / 600
= 0.825 kW
Additional Useful Hydraulic Power Generated
0.825 – 0.583
= 0.242 kW
The Marzocchi pump produces approximately 41.5% more hydraulic output power while consuming essentially the same electrical power from the motor.
Equivalent Power Saving Analysis
To produce 0.825 kW hydraulic output using the lower-efficiency pump, a larger motor would typically be required.
Additional hydraulic power available from Marzocchi pump: 0.242 kW
Daily Energy Saving
0.242 kW × 12 hours/day
= 2.904 kWh/day
Annual Energy Saving
2.904 × 365
= 1,060 kWh
Annual Electricity Cost Saving
Assuming industrial electricity tariff of ₹8 per kWh:
1,060 × ₹8 = ₹8,480 per year
Assuming ₹10 per kWh:
1,060 × ₹10 = ₹10,600 per year
Conclusion
The testing clearly demonstrates the performance advantage of the Marzocchi EK1P-S-5-G gear pump over the China Hydraulic GP-F203.2 pump.
For the same 1 HP IE4 motor and identical current consumption:
10% higher flow output
28.6% higher pressure capability
41.5% higher hydraulic power output
Potential energy saving of approximately 1,060 kWh per year
Annual electricity cost reduction of ₹8,500 to ₹10,600
The results confirm that investing in a higher-efficiency gear pump such as the Marzocchi model can significantly improve hydraulic system performance while reducing long-term operating costs.
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