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Pressure Boosters — Functionality, Types, Application, and Selection Criteria

Pressure boosters increase an existing operating pressure without additional compressor power by concentrating compressed air, hydraulic oil, or other media to a higher output pressure. In industrial applications, they provide targeted pressure boosts for tools, presses, or testing equipment when the main system delivers less peak power. Crucial aspects include design, materials, sealing systems, and connection variants, as these determine operational safety, service life, and maintenance intervals.

Operating Principle and Types

Pressure boosters operate on hydraulic or pneumatic principles. Pneumatic boosters use piston or diaphragm technology to generate an increased outlet pressure from a lower inlet pressure. Hydraulic pressure boosters — often referred to as intensifiers — transfer fluid volume from a large to a small piston area, thereby increasing the pressure proportionally to the area ratio. Other designs include diaphragm-based boosters without piston guidance, two-stage boosters to minimize pressure peaks, and electronic pressure boosters with integrated control valves for precise setpoint control.

Materials and Surfaces

The choice of material depends on the medium, pressure level, and environment. Housings are typically made of structural steel, stainless steel (AISI 304/316), or aluminum. Stainless steel is suitable for corrosive or hygienic environments, while aluminum offers weight and cost advantages at moderate pressures. Pistons and guides require hardened surfaces or coatings such as nitriding, hard chrome plating, or PTFE-based coatings to reduce friction and wear. Seals are made of NBR, FKM (Viton), EPDM, or PTFE contour seals, depending on temperature and media requirements; for high-temperature applications, graphite or metal bellows are used.

Connections, Interfaces, and Mounting

Pressure boosters are supplied with various connection standards: BSP/ISO 7, NPT, SAE, or flange connections according to DIN/EN. The choice of connection size influences flow rate and throttling losses; a line that is too small leads to pressure losses and overheating of the medium. Mounting is either in block design directly on the unit or in installation housings with spring and screw connections. Vibration-damping bearings and elastomer seals at the fastenings reduce transmissions to sensitive systems. Electrical interfaces for electronically controlled models are usually standardized fieldbuses (PROFIBUS, EtherNet/IP) or analog signals (0–10 V, 4–20 mA) for integration into control systems.

Sealing Systems and Maintainability

Sealing systems are critical for pressure boosters. Static seals are selected from PTFE composites or elastomers with appropriate hardness. Dynamic seals on pistons require coordinated material pairings and lubrication concepts. In hydromechanical intensifiers, metal-to-metal seals and O-rings with redundant securing are common to prevent leaks at high pressures. Replaceable seal kits and modular cylinder housings facilitate maintenance. Maintenance plans should include seal inspection, guide clearance control, and lubricant inspection. Spare parts lists and service kits reduce downtime.

Fields of Application and Practical Examples

Pressure boosters are used where peak loads are required or where local pressure increases are to be realized without dimensioning larger supply units. Typical industries include metal forming, hydraulic presses, assembly automation, test benches, packaging machines, and railway technology. Below are three structured practical examples:

• Hydraulic deep drawing press: In a production line for body panels, a hydraulic pressure booster serves as a pressure reserve for the drawing die. An intensifier locally increases the hydraulic pressure from 200 bar to 700 bar to drive the punch without having to design the central system for 700 bar. Advantage: lower investment costs, reduced energy consumption during normal operation, and only short-term peak load on the pump. Material requirements: hardened piston rods, FKM seals, stainless steel fittings for coolant splashes.

In the second example, a pneumatic pressure booster is used in assembly to supply screwdrivers with high tightening torque. The central compressed air supply delivers 6 bar, and the booster locally increases it to up to 12 bar in short pulses. This allows the use of compact screwdrivers without large-dimensioned compressors. Connections: M5 plug connectors or G1/4 hose connections; seals: NBR, lubricant-free design for clean manufacturing environments.

The third example shows a test bench for leak tests of cylinder heads. Here, an electronically controlled pressure booster is used to finely regulate test pressures and specify pressure ramps. The control system provides setpoint specification via ProfiNet, measures return pressure, and regulates valves for pressure stabilization. High-pressure seals made of PTFE and metallic retaining rings ensure zero leakage over long test cycles.

Selection Criteria and Calculation

When selecting, the inlet and outlet pressures, volume flow, operating frequency, medium, temperature range, and integration requirements are decisive. For dimensioning hydraulic intensifiers, the area ratio of the piston area A1/A2 is central: Output pressure = Inlet pressure × (A1/A2). The available volume displacement per stroke determines the cycle time. For pneumatic boosters, compressor speed, air quality (oil/water content), and switching cycles are crucial. Equally important are permissible leakage rates and the protection class (IP) for dusty or humid environments. To simplify targeted selection, check at least the following points:

• Inlet and target pressure, volume requirement, medium type, temperature range, connection standard, control requirements

Integration, Safety, and Standards

During installation, safety requirements (e.g., EN ISO 13849 for controls, DIN EN 982/ISO 4414 for compressed air) must be observed. Shut-off and relief valves must be mounted accessibly. Overpressure protection and check valves prevent pressure peaks in supply lines. Electronic models require suitable protection circuits and functional monitoring; safety-related shutdowns are mandatory for high-pressure applications. Documentation and conformity declarations facilitate CE marking and commissioning tests.

Procurement, Configuration, and Service

When ordering, parametrization options, individual flange variants, and material specifications must be clarified. Manufacturers often offer configuration tools or consulting support. For long-term operational safety, maintenance contracts with defined replacement intervals, training for maintenance personnel, and availability guarantees for spare parts are recommended. Additional information on technical components and solutions can be found on our technology page: https://maku-industrie.de/technik. For specific case studies and application examples, see: https://maku-industrie.de/anwendungsbeispiele.

Service Life, Costs, and Total Cost of Ownership (TCO)

Service life depends on material pairing, operating parameters, and maintenance. Higher initial investments for stainless steel versions or hardened components pay off through longer service life and less wear. TCO includes acquisition, installation, energy consumption, spare parts, and downtime costs. Simulate load cycles to identify wear components and strategically stock spare parts. For high-pressure applications, redundancy planning for critical boosters should be provided to minimize downtime.

FAQs

1. Which seal types are suitable for high-pressure boosters?

For high-pressure applications, hybrid PTFE sealing systems, FKM O-rings with metal backing rings, and metallic bellows are used. The selection depends on the medium temperature, chemical resistance, and dynamic wear of the piston stroke.

2. How is the required power for a hydraulic intensifier calculated?

Calculate the area ratio A1/A2, multiply the inlet pressure by the desired outlet pressure, and determine the required volume per stroke. The required pump power results from volume flow × differential pressure, plus a reserve for efficiency losses.

3. Can a pressure booster be used in hazardous areas?

Yes, provided the device is ATEX/IECEx certified accordingly and the electrical components meet the required protection classes. Pneumatic versions without electrical parts are often easier to approve but require suitable material selection and fastening to prevent sparks due to friction.