I have noticed that my HG-One grinds are much less fluffy than the Vario. For a typical espresso grind, I can probably fit 2-3 more grams from HG-one into a double PF than the Vario (prior to tamping). I'm wondering if this a characteristic of large conicals, or hand grinders, or none of the above. Anyone else seeing this?

Also, not sure what it means, if anything. I would say on a purely subjective comparison, the Vario grinds look better because they're so fluffy and light. Maybe some of this is due to stirring of the grinds required for distribution in the HG-One.

I'd think that a motorized grinder would create greater air turbulence and therefore a fluffier grind.

Queue the other answers that highlight why I'm wrong.

From the grind path of vario vs HG one, the grounds are stirred in the carrier prior to being dispensed, where as HG one grinds fall directly. WDT will puff them up a bit.

Conical grounds are also more shaven in shape than crushed, so they lie flat in a more compact way. See: Titan Grinder Project