Pump efficiency is no longer optional — it is an imperative

Drawing on insights from a recent Sulzer whitepaper, Chris Callander, editor of Flow magazine, argues that pump systems operators must take deliberate steps to improve the performance of their pumping systems — not only as an environmental obligation but as a strategic opportunity for long-term cost savings.

Pump systems have long been the quiet workhorses of industry. They run day and night, often unnoticed, yet their energy footprint is immense. More than one-fifth of the world’s electricity consumption comes from pumps, and in some plants, they account for as much as 90% of total energy use. In an era of volatile energy prices and tightening carbon targets, overlooking pump efficiency is a costly mistake.

A recent Sulzer whitepaper, titled “The multi-million-dollar pump efficiency optimization opportunity”, makes clear that there is a huge financial opportunity hidden within existing pump fleets. Across 464 pumps studied, the majority were found to be running outside their preferred operating region for much of the time. The consequence is wasted energy, unnecessary emissions, and escalating operating costs.

Optimisation without replacement

A crucial message from the report is that optimisation does not automatically require replacement. Many improvements can be achieved during scheduled overhauls or as part of planned repairs. Hydraulic upgrades, advanced coatings, and precision-engineered components manufactured through modern methods can bring ageing pumps closer to their best efficiency point without the disruption and expense of complete replacement.

In one case study, a European oil and gas operator achieved more than 5% efficiency gains and €11.7 million in annual savings simply by upgrading hydraulic components within existing barrels. Another example from Southeast Asia demonstrated that using laser scanning and advanced manufacturing techniques to overhaul boiler feed pumps delivered significant energy savings with a payback period of less than three years.

The environmental and financial imperative

The environmental necessity is undeniable. A modest one per cent global improvement in pump efficiency could save the equivalent of New Zealand’s entire annual electricity consumption. Given the commitments made at COP28 to double the rate of energy efficiency improvements before 2030, pump operators cannot afford inaction.

Yet the financial case is just as strong. Sulzer’s analysis suggests that operators could save an average of $28,000 per pump per year, with a significant proportion capable of delivering savings exceeding $100,000 annually. When scaled across fleets, the potential becomes transformative. Contrary to the common perception that efficiency projects take decades to pay back, the data shows that meaningful returns can be realised in the medium term – and often far sooner.

A call to act deliberately

For pump system operators, the pathway is clear. Auditing current performance, targeting upgrades during scheduled downtime, and embracing advances in materials and digital analytics can deliver both cost and carbon reductions. Optimisation is not a luxury or a future aspiration; it is a necessity that pays for itself more quickly than many assume.

Industrial leaders who view pump efficiency not as a compliance exercise but as a strategic lever will find themselves better positioned for both the environmental challenges and the financial realities of the decade ahead.

If you would like to read Sulzer’s whitepaper, it can be downloaded from go.sulzer.com/energy-optimization-whitepaper