Despite being responsible for 20% of global electricity demand, pumps are rarely prioritised in energy efficiency strategies, with many operators focusing instead on larger assets such as turbines or boilers, according to Sulzer. However, according to the company’s latest study, most pumps have ‘substantial room for improvement’, which could offer companies millions of dollars in energy savings.

Analysing the real-world performance of 464 pumps across the oil, gas and power sectors, Sulzer found that 68% of pumps operated outside of their preferred operating region (POR) for more than half of their run-time, and 44% operated outside POR more than 80% of the time. Over 17% were found to be running in restricted or limited zones for the majority of their operations. ‘This kind of prolonged inefficiency can significantly increase energy costs, shorten equipment lifespan, raise the risk of unplanned downtime and lead to avoidable environmental impact from excess energy-related emissions,’ says Sulzer.

‘Modest efficiency improvements could unlock substantial cost savings,’ it continues. The company estimates average savings of $28,000 per pump per year are possible by operating closer to the pump’s best efficiency point (BEP), without requiring major changes to surrounding systems or processes. More than 25% of pumps could save $50,000 annually, while 10% could exceed $100,000, it suggests. In some cases, individual pumps could deliver between $150,000 and $500,000 in annual savings through targeted, technically feasible upgrades – ‘offering a compelling return on investment’, reports Sulzer.

‘These aren’t theoretical numbers, they’re real inefficiencies happening right now,’ comments Ravin Pillay-Ramsamy, Services Division President at Sulzer. ‘Too often, pumps are considered reliable and left alone, but our data shows that there is meaningful value to be gained by re-examining performance. The opportunity is significant and the path to capturing it is simpler than most expect.’

The newly released white paper, based on operational data monitored over 12 months using Sulzer’s pump analytics platform BLUE BOX, also highlights geographic and sector-specific trends.  

Downstream operators were found to have the least efficient pump fleets, with more than 80% of pumps running outside their preferred range for the majority of their operating time. This represents one of the biggest opportunities for improvement, according to Sulzer.  

Geographically, the largest savings potential was identified in the Americas, where 42% of pumps analysed could each save $50,000 or more annually. In one example, pumps across a single US pipeline could save over $1.5mn/y with performance improvements.

In another example, one upstream European oil and gas operator was shown to have saved €11.7mn in operating costs and carbon taxes, and more than 20,000 tonnes of CO₂ through targeted upgrades.

Sulzer launched an Energy Optimization Service in April 2025. The service includes digital audit, retrofit implementation and long-term monitoring.

The company suggests that improving the energy efficiency of all of the world’s pumps could save around 59 TWh/y – ‘equivalent to the entire consumption of countries such as Singapore, Portugal and New Zealand’. However, in most instances ‘a much larger saving is possible’ it says. For example, retrofitting an old pump with a new, high-efficiency design ‘typically reduces energy consumption by between 3–20%, and in some cases, by up to 50%’.