Part of the difference could be due to inaccuracies in the gauges, part of it due to where the two gauges are measuring pressure (onboard gauge measures before the gicleur (orifice) in the grouphead, portafilter gauge measures after the gicleur), and part of it due to the behavior of pressure relief valves under different flow rates. Greg elaborated on this latter point in
Why difference in pressure between blind filter and brewing? from the
FAQ:
gscace wrote:Now lets examine why there is a difference in pressure between pumping against a blind filter and when brewing coffee. When water delivered by a pump is forced through the pressure relief valve, the plunger within the valve is forced away from the plunger seat, as needed to accommodate the volumetric flow rate through the valve. When this happens, the new equilibrium pressure between the water and the pressure relief valve plunger is higher than the cracking pressure because the piston has moved away from the seat and the spring is further compressed. The change in pressure is dependent on the amount of liquid flow through the valve, the diameter of the plunger, the geometry of the outlet orifice that is uncovered by the plunger's motion, and the spring constant. The pump produces excess flow rate at 9 bars, compared to what is needed to brew espresso. This means that there is always excess water flowing through the pressure relief valve to some degree when the machine is brewing coffee. Vibe pump systems using relatively long-traveling pressure relief valves, such as the one being discussed here, produce large pressure differences between actual brewing and pumping against a blind filter. In the case of pumping against the blind filter, all of the pumped water flows through the relief valve. When brewing, a large fraction of the initial water flow is absorbed by the coffee cake at the start of the extraction process. Then a smaller, but still very substantial fraction of the total flow exits the system through the group and into the cup. Thus the equilibrium pressure imparted by the relief valve is less when brewing than when pumping against the blind filter.