What is Hydraulic Intensifier?

hydraulic intensifier

A hydraulic intensifier is a mechanical device that increases the intensity of liquid pressure. It captures the energy of large volumes of low-pressure liquids. Some hydraulic machines require high pressures to function, which cannot be achieved with a pump.

Hydraulic presses, hydraulic rams, hydraulic jacks, and other similar machines are examples of hydraulic machines. In order to achieve the required amount of pressure, these machines require high pressure. Between the pump and the implement, a hydraulic pressure booster is installed.

Single-acting and double-acting are the two types. Only single-acting hydraulic intensifiers are covered in this section. That is, it only delivers high pressure fluid during the downstroke. Hydraulic intensifiers with dual acting provide high pressure on both strokes.

Working Principle

A machine of this type can be built by mechanically connecting two pistons, each of which operates in separate cylinders of varying diameters. The force and stroke length are the same because the pistons are mechanically linked. If the diameters differ, the hydraulic pressure in each cylinder will vary in proportion to its area.

Pressure is generated by smaller pistons. Pressure is inversely proportional to the square of the diameter because it is inversely proportional to area.

The stroke of the piston limits the intensifier’s working volume. This restricts the amount of work that can be accomplished with a single stroke of the amplifier.

This limits its utility for machines that can complete the job in a single stroke. They are frequently used when a powerful hydraulic jack is required but there isn’t enough space for the necessary cylinder size, lifting capacity, and system pressure. Using an intensifier mounted on the jack’s outside gives you more pressure, allowing you to use a smaller cylinder for the same lift. Intensifiers are also used in machines like hydraulic presses where higher pressures are required and a sufficient supply is already available.

Some small intensifiers are designed with a stepped piston. It is a two-sided piston with two different diameters, each of which works with a different cylinder at each end. The overall length is more than twice as long as the stroke, and the design is straightforward and compact. Furthermore, two seals, one for each piston, should be provided, and the space between them should be vented. 


  • Hydraulic intensifiers are used to deliver high-intensity, high-pressure output on demand.
  • It is used when a pump is insufficient to provide the required high pressure intensity.
  • Hydraulic presses, rams, cranes, and elevators, for example. Most commonly used when high pressure is needed to lift loads.


  • Hydraulic intensifiers are small, portable devices that are simple to use and control.
  • If desired, it can be mounted directly on the hydraulic machine.
  • Equipment that is small and saves energy.
  • If you consider its features, it is a low-cost device. A simple and cost-effective operation can save a lot of money. The work is simple, and the operation is safe and cost-effective.
  • It runs at high speeds and can be started and stopped as needed.
  • It can be installed between the pump and the hydraulic machine because it is simple to connect to the pump.
  • It is extremely simple to use and control.
  • Constant force and pressure is applied throughout the working process.


  • The main disadvantages of hydraulic intensifiers are the same as those of all other hydraulic systems. There is a liquid leak.
  • The hydraulic fluid used is corrosive and can cause machine damage.
  • Another significant disadvantage is the risk of spilled liquids igniting. So work carefully and try to avoid even the smallest leaks.
  • This system requires extensive maintenance.


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