A PEM fuel cell power plant system (10) has a process air pump (26), which may be a fan, a blower or a compressor, with an adiabatic efficiency of between 40% and 70%. The process air at the inlet 27 of the cathode reactant gas flow field 16 is between 1.07 atmospheres and 1.85 atmospheres, and may be at an optimal pressure for maximum overall system efficiency P={0.45+2.6E-1.8E.sup.2} atms.+-.0.2 atms where P is the air inlet pressure and E is the adiabatic efficiency of the process air pump.