An explanation of industrial hoses with a list of manufacturers
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An industrial hose is a durable and precision constructed hose used to transfer and transport liquids, gases, and other materials for industrial applications. They are made of materials that are capable of withstanding the effects of the substances being transported and industrial environments. The linings of industrial hoses are carefully chosen to prevent the contamination of the substances being transported. Rubber, flexible metals, and various forms of plastics are commonly used. The success of industrial hoses is dependent on the selection of their structural materials and how they are manufactured.
The selection of industrial hoses for an application is based on a specific set of parameters in order to match the type of hose to the transported materials. The key factors in the selection process are pressure and temperature range, bend radius, burst pressure, number of layers, and inner and outer diameters (ID and OD). Due to the nature of the liquids industrial hoses handle, there are stipulations and regulations regarding their use, which are mainly categorized by products for human consumption and industrial substances.
The structure of industrial hoses includes a layer of reinforcement that is braided, spiraled, woven, or knitted. This aspect of the reinforcement layer prevents industrial hoses from collapsing and increases their external durability. The reinforcement layer is necessary for an industrial hose to meet the requirements of high-pressure applications and enables it to retain its flexibility and capabilities for resisting environmental conditions.
The manufacture of industrial hoses varies in accordance with the basic materials used to produce them. Thermoplastics, silicone, Teflon (PTFE), rubber, metal, polyurethane, nylon, and polyvinyl chloride (PVC) are some of the materials that are used. Each type of industrial hose has properties that meet the requirements of a specific application. The process for manufacturing industrial hoses is chosen to ensure a hose’s ability to endure the environment where it will be used.
As with any industrial tool, the design and engineering of an industrial hose includes processes that ensure a hose’s resilience, strength, durability, and performance. Each aspect is carefully considered to ensure the highest quality. How industrial hoses are made is dependent on their basic materials. Regardless of these differences, the structure of all industrial hoses includes three basic factors – inner tube or layer, reinforcement layer, and outer cover.
Inner Tube or Layer – The inner layer of industrial hoses normally consists of synthetic rubber, PKR rubber, EPDM rubber and butyl rubber. Each of these materials have different reactions to fluids that pass through an industrial hose. They are chosen in accordance with their compatibility to endure the fluids or gases they may transport. The inner tube of an industrial hose has to be able to withstand the heat and pressure it will experience during its use.
PKR rubber is chosen for its ability to endure petroleum products. Ethylene propylene diene monomer (EPDM) is a polymer that can withstand high temperatures including fireproof hydraulic fluids. Synthetic rubbers can handle a wide range of fluids and gases due to their containing acrylonitrile as part of their chemical makeup.
Reinforcement Layer – The quality of an industrial hose depends on the strength of the reinforcement layer that surrounds the inner tube layer and gives an industrial hose its resilience. The sheath of the reinforcement layer is braided or spiral wound but can also include knitted textile yarn. The strength of the reinforcement layer of an industrial hose determines its working pressure. Each of the methods used to form the reinforcement layer, braided, spiral, or knitted, determines a hose’s resistance to pressure and its flexibility.
Spiral and braided reinforcement layers are supported by steel or synthetic fibers such as nylon or polyamide. These types of materials are chosen for their strength and flexibility.
Outer Layer – The outer layer of an industrial hose is the protection layer that covers the tube layer and reinforcement layer. It is capable of resisting the effects of the environment, such as UV rays, impacts, abrasions, and extreme temperature changes. The protective properties of the outer layer necessitate the use of highly resilient materials that are made of synthetic rubbers and PVC, which are resistant to wear and the effects of exposure to oils and chemicals.
Due to the variety of uses of industrial hoses, their outer layers can take several forms to meet the requirements of an application or process. In certain instances, the outer layer requires increased flexibility to provide a tight bending radius or enhanced abrasion protection to endure harsh and hazardous environments. As with several aspects of industrial hoses, the materials and construction methods of the outer layer are carefully engineered to meet specific pressure requirements, a variety of temperature ranges, and to extend the useful life of an industrial hose.
The manufacturing of industrial hoses takes different forms depending on the materials being used to produce them. In all instances, the complexity of the processes involves several steps to ensure the final product has the stamina and strength to endure the requirements of industrial operations and applications. The materials and processes used to produce industrial hoses involve a long list methodically planned procedures that involve the use of rubber, PVC, thermoplastics, silicone, Teflon, various metals, polyurethane, nylon, and specialty materials.
Rubber hoses are engineered to withstand extreme pressure. The methods used to produce rubber industrial hoses include extrusion, spiral wrapping, calendaring, hand layup, and molding. The determination of the process used is partially dependent on the size of the hose with small industrial hoses being produced using extrusion while larger hoses are manufactured through spiral wrapping.
Stage 1 – Selection of Materials – For rubber industrial hoses, the process begins with determining which type of rubber will be used. Each of the different types of rubber, natural or synthetic, has properties that are appropriate for industrial hoses. The choosing process involves selecting the type of rubber that best fits the application for which an industrial hose will be used.
The capabilities of the selected rubber can be enhanced with additives, such as carbon black, plasticizers, and antioxidants. The inclusion of these materials makes it possible to customize a rubber to meet the specific requirements of an application.
Stage 2 – Industrial Hose Forming – After the selection process, the raw rubber is subjected to various manufacturing processes, which involve extrusion and spiral wrapping. The initial phase of the process involves the extrusion of the inner tube, where the raw rubber is forced through a die that has the dimensions and diameter of the tube. The process is carefully monitored for consistent wall thickness and adherence to the hose’s ID.
Stage 3 – Applying Reinforcement Layer – The application of the reinforcement layer can take several forms, including braiding, spiraling, or knitting textile fibers or wire around the extruded tube. The spiral method consists of wrapping wire or textile material around the inner tube at a specific angle with the wires or textiles being parallel to each other. Multiple layers are applied at opposing angles to add to the strength of the wrapping.
Braiding involves interweaving the strands of metal or synthetic fabric, which is repeated in order to achieve the strength required for an industrial hose. The choice of the braiding technique is designed to enhance an industrial hose’s ability to withstand high pressure and impact from external forces without damaging the hose's flexibility.
Stage 4 – Vulcanization – Vulcanization is a common process used during the manufacturing of rubber products, which is necessary to strengthen rubber and improve its properties. During vulcanization, rubber is heated with sulfur that causes the polymer chains in rubber to cross link, creating a three-dimensional structure. The results of the process are increased strength, deformation resistance, increased elasticity, resistance to chemicals and solvents, and resistance to changes in temperature.
Rubber, in its natural state, lacks strength and durability. It is a chewing gum-like substance that can be stretched, twisted, and compressed, much like bread dough. Crosslinking during vulcanization hardens rubber by connecting the parallel polymer chains.
Stage 5 – Application of Outer Layer – The application of the outer layer involves an additional extrusion process that is applied over the reinforcement layer. The process involves heating rubber and pressing it through a die over the reinforcement layer. A second vulcanization may be necessary to harden the outer layer. The material chosen for the outer layer is dependent on how and where an industrial hose will be used. Dangerous and extreme environments require stronger and more robust protective materials.
A key factor in the application of the outer layer or cover is the selection of the material to be applied, which can be rubber, PVC, or thermoplastic. Once the material is chosen, it is mixed with additives to enhance its resistance to UV rays, increase longevity, and protect the hose against abrasions. The cover material is heated and compressed against the reinforced layer. The process of the extruder is performed at a consistent pressure and temperature to ensure a smooth even texture to the outer layer.
Stage 6 – Finishing – After the final extrusion, an industrial rubber hose is cooled to stabilize its form. The cooling process can be completed rapidly or slowly to prevent damaging the hose and assists in helping a hose retain its basic structure. During cooling, the outer layer solidifies and hardens to create a protective barrier for the inner and reinforcement layers.
At the completion of the manufacturing process industrial hoses are hundreds of feet long. Prior to the installation of fittings, the long lengths are cut to specific applicable dimensions that are required by an application. As a part of the finishing process, industrial hoses are labelled and marked with their part number, pressure rating, manufacturing date, and batch number. This additional step makes it possible to trace a hose’s production lot if there are quality concerns.
PVC is a thermoplastic created from the polymerization of vinyl and chloride. Industrial hoses manufactured using PVC are lightweight and cost effective with a lower petroleum content than other polymer materials. They are used in applications where flexibility, durability, and resistance to chemicals are critical. Like rubber industrial hoses, PVC industrial hoses come in a wide variety of sizes, lengths, and colors.
As with rubber industrial hoses, the manufacture of PVC industrial hoses involves several steps that include extrusion, wrapping or braiding, and a second extrusion. Most of the steps of the process match those of rubber industrial hoses with the exception of raw materials selection.
Stage 1 – PVC Material Preparation - The production process begins with mixing of PVC resin with additives that include stabilizers, pigments, processing aids, plasticizers, and lubricants. The unique properties of PVC resin allow its formulation to be adjusted to meet the requirements of an application or process. The percentages of each additive are determined by the requirements of an application to produce specific properties.
The mixing of the additives and PVC resin is referred to as a dry blend compounding or dry blending that is performed in a high-speed mixer that generates heat to combine the additives with the resin particles. The product of the process is a dry mix that has the right texture for extrusion.
Stage 2 – Extrusion – As with rubber industrial hoses, the first step in PVC industrial hoses is the extrusion of the inner layer or tube. The difference between the processes is the way the PVC resin is fed into the extruder. With rubber extrusion, raw rubber is placed in the extruder and forced along the barrel of the extruder toward the die. Since the PVC compound is in a dry pellet like form, it is fed into the extruder through a hopper that is placed at one end of the barrel.
The barrel of the extruder is heated to melt the PVC compound. In addition, a helical screw moves the compound along the barrel as it is melted such that it can be compressed through a die. In the die, the melted PVC compound is separated into different streams. Once forced through the separation mechanism, the melted compound comes together to produce a tube shape. The result of the process is a long tube that forms the inner layer or tube of an industrial hose.
Stage 3 – Reinforcement Layer – The formation of the reinforcement layer is the same as it is for rubber industrial hoses. Braiding, knitting, weaving, or spiral forming are used. The nature of the reinforcement is dependent on the type of industrial hose and its use. Metal wire or strips and textile fibers serve as the reinforcement materials. Unlike rubber industrial hoses, PVC industrial hoses do not include vulcanization after the application of the reinforcement layer.
Stage 4 – Outer Layer – The outer layer of PVC industrial hoses is applied using a second extrusion process. The material is a PVC compound that is melted and placed over the reinforcement layer. The colors available for the outer layer include black, red, yellow, blue, and customizable ones. The wide array of colors makes it possible for OEMs or ODMs to customize industrial hoses to match the branding of their customers.
Stage 5 – Cooling and Cutting – The cooling process is carefully monitored to ensure the integrity of the hose. The rate of cooling determines the distinct properties of a PVC industrial hose and necessitates care, supervision, and control. When the lengths of hose are sufficiently cooled, they are cut to match the requirements of an application. At the completion of the cutting process, some PVC industrial hoses will have fittings applied while others are left plain for custom fittings.
Although rubber and PVC industrial hoses are very common, there is a wide range of other materials used to produce various types of industrial hoses. In some cases, the materials are proprietary to a manufacturer who specializes in a certain type of industrial hose. Different types of plastics and fibers are commonly used to produce industrial hoses as well as metals.
Thermoplastic Industrial Hoses – Thermoplastic industrial hoses are flexible and have a high pressure rating.
Silicone Industrial Hoses – Silicone industrial hoses are made by shaping uncured silicone. They are valued for their high temperature resistance.
Teflon Industrial Hoses – Teflon industrial hoses are manufactured in the same way as PVC hoses. They have high chemical resistance with exceptional flexibility and strength.
Polyurethane Industrial Hoses – Polyurethane industrial hoses are flexible and abrasion resistant with exceptional resistance to oil and chemicals. They are produced using the extrusion method.
Metal Industrial Hoses – Metal industrial hoses are produced by forming thin sheets of metal into tubes with a reinforcement layer that includes braided or spiral wound wire. They are widely used in applications where industrial hoses have to keep their shape in vacuum conditions.
Nylon Industrial Hoses – Nylon industrial hoses are produced using the extrusion method using nylon resin. They are commonly used in high pressure hydraulic systems and air brakes due to their strength and thermal stability.
Each of the materials listed above are used in unison to form compound industrial hoses where the above materials are combined with polyamide, polyester, or polypropylene. These types of hoses are formed by winding the material around a mandril with the layers bound together with adhesives or by being melted together. Compound industrial hoses, due to their unique structure, can be used in a wide range of applications. Their structure and design are focused on a specific process, application, or operation that benefits from their unusual composition.
Industrial hose fittings and connectors are an essential part of industrial hoses. They make it possible for an industrial hose to be attached or connected to equipment, machinery, and other hoses. Solid reliable fittings and connectors ensure the safety of an industrial hose and the efficient transfer of fluids and gases. There are an endless number of types, sizes, and forms of fittings and connectors, each of which are designed to connect with a specific application or process.
As with other aspects of industrial hoses, the materials for fittings and connectors are chosen in accordance with the application for which an industrial hose is made. The most common materials are stainless steel and brass, which are resistant to corrosion and rust. Steel, stainless steel, brass and aluminum are generally used by manufacturers.
Steel is used due to its strength, durability, and temperature range of -65°F up to 500°F (-53.89°C up to 260°C).
Stainless steel is resistant to corrosion, highly durable, and tough. Since it is available in several grades, it is ideal for customizing a fitting or connector to a specific application.
Brass fittings are able to withstand the demands of high temperature applications and have a temperature range of -65°F up to 400°F (-53.89°C up to 204.44°C). They have excellent corrosion resistance and can endure up to 3000 PSI.
Aluminum fittings have an exceptional strength to weight ratio and are resistant to corrosion. Their lightweight and strength are the reason for their wide use.
Fittings and connectors for industrial hoses are an essential part of the success of an industrial hose and their safe use. The varieties of fittings and connectors are designed to meet the requirements of an application and are carefully selected during the design phase. Secure connections between equipment and hoses or between hoses ensures the efficient completion of an application.
Cam and groove threaded fittings, referred to as camlocks, kamlocks, or quick disconnects, are the most widely used form of industrial connector. Their sizes range between 1/2 in up to 8 inches and are made of all forms of metals. Female couplers of cam and groove fittings have arms that line up with a groove in the male adapter. When the arms are closed, the male adapter is pulled into the female coupler, producing a tight and secure seal and connection. The wide use of cam and groove fittings is due to their ability to be quickly disconnected.
Compression fittings are for connecting two hoses using a compression nut and ferrule. They are ideal for handling high pressure applications and forming a tight, reliable seal. The structure of a compression fitting includes a sleeve, nut, and body where the sleeve seals the connection when the nut is compressed into the body.
Ball and sleeve fittings have a double pin locking lever for connecting and disconnecting the fitting. The outer sleeve of the fitting connects to an inner ball fitting. When the sleeve retracts, the ends of the fitting disconnect. Push to connect ball and sleeve fittings are ideal for applications that require frequent disconnection and connection of hose sections.
Barbed fittings are applicable for a few industrial hose applications and are not used for high pressure applications. They are connected to an industrial hose by being forcibly thrust into the tube layer of an industrial hose where their tapered stub and ridges prevent the fitting from being easily extracted. Barbed fittings normally have a threaded end that is located opposite to their ridges.
There are several varieties of threaded fittings, which vary according to the placement of the threads, their shape, and the size of the threads. Screw threads can be placed on the inner or outer surface of a connector and can be straight or tapered. Of the two types of screw threads, tapered threads provide the tightest seal for gases and liquids being transferred under pressure. Precision threads, known as dry fit, provide an exceptional seal. The sizes of threads are standardized in accordance with the specification published by National Pipe Thread (NPT) and British Standard Pipe (BSP). Standards vary according to the number of threads per inch (TPI).
Couplings connect hoses using solvent welding, soldering, or threading. They are used to bridge the gap between hoses and components in a system.
Tee connectors make it possible to connect two supply lines to a lead hose. They make it possible to split or combine materials. Tee connectors get their name from their T shape and two right angles. A connector that has a function that is similar to tee connectors is the wye connector that serves the same functions but has the shape of a Y.
In addition to wye and tee connectors, there are cross connectors that have the shape of tee connectors but with an additional hose inlet or outlet. They are not as stable as tee connectors but make it possible to have one inlet and three outlets or three inlets and one outlet, depending on a process’s requirements.
Sandblast fittings connect hoses with sandblasting nozzles. They are claw type fittings where the hose is inserted inside a ferrule to reinforce and strengthen the connection. Sandblast fittings have their connections further strengthened by screws that screw down into the ferrule. Once the fitting is attached to the nozzle, pins are used to further secure the coupling due to the pressure produced during sandblasting.
The eight fittings and connectors described above are a very small sampling of the many industrial hose fittings that are available. Industrial hose manufacturers work with fitting companies and customers to ensure selected fittings and connectors meet the requirements of an application. Proper fittings are a final and necessary part of industrial hose construction that ensure the efficiency of a process and the safety of workers.
Several types of industrial hoses are offered by manufacturers due to the many applications and processes that depend on them. Industrial hose manufacturers are constantly developing and introducing new types of industrial hoses to meet the changing specifications and demands of modern industry. Each type of industrial hose is classified according to its purpose and usage.
The term industrial hose is a broad term that covers a wide range of hoses. When customers are planning on purchasing an industrial hose, they can be overwhelmed by the hundreds of hoses on the market. The best solution is to work with an industrial hose manufacturer that is an expert on types of hoses, their composition, uses, and fittings.
Industrial hoses are a critical part of industrial operations. They are used for conveying, suctioning, and discharging of air, water, chemicals, petroleum products, and gases. The high quality of industrial hoses enables them to withstand extremes in temperature, high pressure, and harsh hazardous chemicals. They are exceptionally durable, flexible, and provide a cost-effective solution for material handling.
Air pressure industrial hoses are made of nitrile with steel braiding and can handle pressures up to 1500 psi. They are designed to transfer pressurized air and must be highly durable, strong, and resilient. Air pressure industrial hoses are used in extremely harsh conditions, such as construction sites, mines, quarries, and saw mills. Medium duty air pressure industrial hoses have fabric braiding and can handle pressures between 400 psi and 600 psi.
Push-on air pressure hoses are a special type of air pressure hose that has a barbed end. They are flexible regardless of the temperature and are easily adaptable to any conditions. When selecting an air pressure hose, it is important to determine the air pressure an industrial hose will need to withstand. The nature of the work of air pressure hoses necessitates that they be highly durable in order to endure their working conditions.
Air pressure industrial hoses normally have quick connect fittings, such as couplers, barbed fittings, and threaded connectors. Fittings are chosen for their compatibility with compressors and air powered tools. An essential aspect of air pressure industrial hoses is their tight seal for leak free performance.
Most chemical hoses are made of ultra-high molecular weight polyethylene (UHMW) or cross-linked polyethylene (XLPE), which are adapted to meet specific temperature and pressure requirements. The choice of the type of material used for a chemical industrial hose is dependent on the chemicals to be handled. Chemical industrial hoses are used for suction and discharge, a factor that further defines the choice of hose. Helical wire reinforcement may be necessary to add extra flexibility and strength.
The use of chemical hoses covers a wide spectrum of industries that include oil and gas, pharmaceuticals, and food and beverage. The key characteristics of chemical hoses are their reliability, strength, durability, and safety. The many sizes of chemical hoses are chosen for their flow rate and pressure limits. The sizes of chemical hoses are determined by the materials being handled with different sizes selected for different applications.
LPG hoses are a unique form of hose that meet UL21 certification requirements for safety, security, quality, and performance. The Canadian Gas Association (CGA) type 1 code includes Canada’s requirements for the handling of natural gas and delivery. The strict requirements for LPG hoses are due to the inability of most industrial hoses to handle the transfer of petroleum products. Rubber hoses are permeated by petroleum molecules creating leaks and destroying the hose. The most common material used to construct LPG hoses is nitrile rubber with textile braids crossed with copper strands with a chloroprene cover.
Small perforated holes are added to LPG industrial hoses, on their outer layer, to act as a membrane that allows gas to escape and evaporate between the inner and outer layers. Without the perforations, blistering can occur due to pressure from the gas causing deformation in the outer layer.
Industrial hoses are widely used in the food and beverage industry for the transfer and transport of ingredients and liquids. The types of materials handled by food and beverage hoses include oil and fatty products, dry materials, and non-fatty products. Industrial hoses for wet non-fatty foods are made of the synthetic rubber chlorinated isobutylene-isoprene, also referred to as chlorobutyl. Nitrile is also used due to its resistance to oil and fatty materials.
Any food and beverage tools are required to meet the standards of the Food and Drug Administration (FDA), which also stipulates the acceptable materials for hose manufacturing. The outer layer of food and beverage hoses is determined by the conditions where a hose will be used with nitrile used for oily environments while EPDM is used for non-oily conditions.
Specialty industrial hoses are designed for the handling of sensitive food products. High temperature conditions necessitate hoses capable of handling bursts of steam. In the beverage market, PVC industrial hoses are used for wineries and breweries. In all instances, the emphasis is on cleanliness and sanitary requirements.
There has been some disagreement regarding hydraulic hoses and whether they fit into the definition of an industrial hose. The contention regarding hydraulic hoses being classified as industrial hoses is the function of hydraulic hoses, which is very specialized and critical to the operation of hydraulic powered equipment.
Industrial hoses have a wide range of functions with their main emphasis being on the transfer and transport of materials. In contrast, hydraulic hoses or tubes are components in machinery and are critical to the function of the equipment. They transport hydraulic fluids to a cylinder under extreme pressure for a mechanism to perform mechanical work. Unlike industrial hoses, hydraulic hoses are designed to work with specific fittings, connectors, and ends, which cannot be substituted to fit any type of hydraulic equipment.
Each hydraulic hose is designed to handle a specific type of high-pressure fluid and fit within the mechanism of hydraulic equipment. They are customized, designed, and constructed for a single function, which is unlike industrial hoses that can perform or transport a wide variety of materials.
Although the materials used to manufacture hydraulic hoses is similar to those used for industrial hoses, the resilience and strength of hydraulic hose materials is far superior to that used for industrial hoses. The inner tubes or layers of hydraulic hoses is chosen for its ability to withstand high pressure and is normally a form of rubber. All hydraulic hoses have spiral or braided steel as part of their reinforcement layer.
Due to the nature of the functions of hydraulic hoses, their outer layer is made of synthetic materials capable of withstanding abrasions, UV radiation, and the harshness of industrial environmental conditions. The strength and endurance of the outer layer determines the longevity of a hydraulic hose.
Welding industrial hoses are pairs of hoses that perform separate functions. They come as twin lines or individual lines. Welding hoses are graded as Grade T for hoses resistant to oil and Grade R for hoses with low oil resistance. Hoses for welding are separated into green for oxygen hoses and red for burning gas hoses.
As with all forms of industrial hoses, welding hoses are divided according to the temperatures they can endure, which can vary from 160°F (71.11°C) for low temperature resistance up to welding operations as hot as 1650°F (898.89°C). The different levels in temperature determine the types of materials used to manufacture welding hoses.
There are many industries, aside from the ones described above, that depend on industrial hoses to transport and handle a variety of materials. The range of industrial hoses includes generic hoses that can be used for an infinite number of applications to customized hoses manufactured specifically for a single function.
Material Handling Industrial Hoses – Material handling industrial hoses transfer abrasive substances, such as sandblasting, concrete, and asphalt.
Bulk Materials Industrial Hoses – Bulk material industrial hoses are large diameter hoses capable of transferring shot blasting material, dry ice, plaster, concrete, cement, sand, gravel, grain, and seeds. They range in diameter from 1/2 in up to 20 inches (13 mm up to 500 mm) with a working pressure of 80 bar.
Steam Hoses – Steam hoses can handle temperatures over 450°F (232.22°C) at pressures over 250 psi.
The above list of industrial hoses provides a sampling of the uses and types of industrial hoses that manufacturers and industrial operations depend on. When making the decision to purchase an industrial hose, it is crucial to work with a qualified industrial hose manufacturer that can provide the alternatives and materials that perfectly match any application or process.
The selection of an industrial hose is a critical part of an operation or application and requires careful consideration. When working with an industrial hose manufacturer, it is important to have some knowledge of the factors that are used to determine the best industrial hose. Providing industrial hose producers with solid factual data can assist in delimiting the selection process and establishing the proper focus.
The type of material to be transported is a major factor in the construction of an industrial hose. Liquids and gases have a different flow rate than granular materials or highly viscous substances. These factors determine the inner (ID) and outer (OD) diameters of industrial hoses. The ID and OD must match the flow rate of the transported materials and fit the available space.
The pressure and temperature of an application radically affects the type of industrial hose and its structure. Since certain plastics and rubbers do not perform well in hostile conditions, it is important to know the operating pressure and temperature of the application for which an industrial hose is being used. Although such knowledge is important to the efficiency of material handling, it is also critical for safety and the prevention of operation failures.
It is often assumed, when speaking of hoses, that they are all flexible and bend easily. While this may be true for some hoses, it is not true for all industrial hoses. When examining an application, it is important to determine how flexible a hose needs to be to meet the conditions. In addition to flexibility, the prevention of crimping is another factor to consider. The bend radius is important for applications where an industrial hose needs to be flexible or move.
The importance of industrial hoses necessitates that they be tested for their pressure limits due to the critical nature of the functions they perform. Since the transport of certain materials builds pressure in a hose, having knowledge of the pressure limit of a hose determines its applicability for an application. As with bending radius, the correct hose with the proper pressure limit helps avoid system failures and danger to employees.
Each industrial hose has a maximum operating pressure. Exceeding a hose’s pressure limit leads to hose failure and hazardous conditions. Industrial hoses for an application should have a pressure rating that meets or exceeds a system's requirements.
The operating temperature for an application should fall within an industrial hose's specified temperature range. Extreme temperatures cause hose materials to become brittle or soften, compromising their integrity and performance.
In line with burst pressure is the number of layers, which increase with the level of pressure a hose must endure. Multiple reinforcement layers improve a hose's resistance to pressure and increase its strength and flexibility. Fewer layers make an industrial hose more flexible and easier to handle. In essence, variations in temperature and pressure are critical to the structure of an industrial hose.
Critical applications, hazardous processes, and sanitary conditions require the oversight of different governmental agencies that provide guidelines regarding industrial equipment. Aside from the FDA, Underwriters Laboratories (UL) provides safety standards for industrial hoses. The organization provides certifications to manufacturers that adhere to their standards.
Each of the steps of the industrial hose selection process are available from qualified manufacturers who adhere closely to published safety standards. Partnering with a manufacturer can significantly simplify the selection process and provide an industrial hose that is perfect for an application.
What material will the hose be conveying? What are the operating pressure and temperature requirements? Will the hose be subject to abrasion, flexing, or chemical exposure? An examination of the specific aspects of an industrial application is a crucial step in the industrial hose selection process.
The material of an industrial hose must be chemically compatible with the substances being transferred to prevent hose degradation, leaks, and potential hazards.
Except for hydraulic hoses, the application of fittings and connectors for industrial hoses varies. Some manufacturers work with their clients in the selection of fittings and connectors that meet the requirements of an application, while other manufacturers leave the application of fittings and connectors to their customers. In some cases, specialty proprietary fittings are used and are attached by a separate company. As with the many aspects of industrial hoses, fittings and connectors are crucial to provide a tight seal and prevent leaks.
One of the dangers in regard to industrial hoses are leachables and extractables, which are substances that migrate from the material of a hose into the product or substance being transported. This particular danger is one of the reasons that the manufacture and design of industrial hoses is so carefully monitored and supervised since very sensitive pharmaceuticals and foods can be contaminated by moving through a hose.
As materials are traveling through a hose, they may remove substances from the hose material, which contaminates the product being transferred. This aspect of industrial hoses is a major concern for the pharmaceutical and medical industries. Extractables endanger the safety and purity of a product and make products ineffective, unstable, and can result in the production of harmful substances. Extractables extract from a hose when in the presence of certain chemicals.
Leachables are a subset of extractables and are substances that migrate from hoses into materials that the hose comes in contact with. As with extractables, leachables can destroy the integrity of a product and have cataclysmic effects. Leachables leach into products from the surface of a hose.
Industrial hoses made of plastic or rubber can be the source of extractables and leachables due the use of plasticizers, lubricants, antioxidants, and additives that have been combined with hose materials to enhance the properties of industrial hoses.
Industrial hose manufacturers that produce industrial hoses that are used for products for human consumption are required to adhere to the stipulations provided by the FDA regarding leachables and extractables. The contamination of pharmaceuticals and foods by leachables and extractables is a major concern of the FDA to the extent that it has developed specific guidelines regarding materials used to produce industrial hoses for food and drug material handling.
Due to the severity of leachables and extractables, food and beverage and pharmaceutical manufacturers regularly test their product for contamination. The testing process identifies the presence of leachables and extractables and determines the extent of the potential contamination. Testing provides data regarding the level of contamination and whether it is within acceptable limits.
There are several factors that are used to determine the risk factors regarding the presence of leachables and extractables. As with environmental hazards, the examination of the dangers of extractables and leachables is in regard to the chemical nature of the contacted materials, the length of time of contact, and an assessment of the potential danger to workers and products.
Industrial hoses and industrial tubing have the same tube-like appearance and come in a wide variety of diameters. Although they share the same dimensions, lengths, and have similar uses, they are distinctly different in regard to applications, materials, and how they are sized. The most telling difference between the two is their structure and flexibility.
Industrial hoses are reinforced with metals or fabrics and normally have three layers, which allows them to endure the pressure and temperatures associated with industrial processes. Industrial tubing is less flexible and tends to be rigid. Their dimensions are set by their OD and wall thickness (WT). While industrial tubes are used for structural applications, industrial hoses are used for a wide range of operations, processes, and applications.
Transport methods are a crucial part of industrial processes. The selection of the type of method is normally between pipes, tubes, or hoses. Although all three are viable, it is essential to select the type that best fits with the material and system. Having an understanding of the benefits of each transport mechanism assists in the selection process.
| Industrial Hoses Vs Industrial Tubing | ||
|---|---|---|
| Feature | Industrial Hoses | Industrial Tubing |
| Flexibility | Flexible | Rigid |
| Wall Thickness | Thicker for Pressure Handling | Thinner Walls |
| Reinforcement | Reinforced with Braiding or Spiraling | Normally Unreinforced |
| Pressure Rating | Medium to High | Low to Medium |
| Size Designation | Inner Diameter (ID) and Outer Diameter (OD) | Outer Diameter (OD) and Wall Thickness (WT) |
| Common Applications | Fluid and Chemical Transfer, Material Handling, and Air and Water Conveyance | Instrumentation, Control Lines, Low Pressure Fluid Transfer, Pneumatic Systems |
| Materials | Rubber, PVC, Polyurethane, PTFE, Composites | Plastics (Nylon, Polyethylene, Polyurethane, PVC), Metals (Stainless Steel, Copper) |
The strength and stability of an industrial hose is capable of powering a hydraulic jack and supplying gas and oxygen to a welder. Slender rigid industrial tubing feeds air to pressure gauges to provide precise measurements. The flexibility and mobility of hoses enables them to be used in an endless number of applications while industrial tubing is restricted to structural and thermal applications.
Plastic tubing is a form of tubing that is manufactured from a mixture of a polymer with a variety of chemicals to form a material that can be solid or flexible. Since its first use in the 1950‘s, plastic tubing has revolutionized industrial processes and has found a use in a wide variety of applications...
Poly tubing is a highly flexible, lightweight, and durable tubing that is produced from polyethylene, a polymer that is made from the polymerization of ethylene. It is a very versatile form of tubing that has break and crack resistant walls...
PVC is a tough chemically resistant synthetic polymer of vinyl chloride used especially for making pipes, films and electrical insulation. It is made by polymerizing vinyl chloride, and...
Silicone tubing is a very tough elastomer that exhibits high strength, flexibility, and resistance. Silicone tubing can be stretched without tearing and is highly versatile. It cannot be weakened with repeated bending and twisting due to...
Plastic channels are plastic products that have linear extruded profiles. They have a constant cross-sectional shape across their axis. They are long and narrow structures, and their depth is relatively short. These products serve a variety of functions and uses...
Plastic extrusion, also known as plasticating extrusion, is a continuous high volume manufacturing process in which a thermoplastic material -- in a form of powder, pellets or granulates -- is homogeneously melted and then forced out of the shaping die by means of pressure...
Plastic materials are objects artificially made from organic compounds called polymers along with other additive components. They possess excellent formability, making them extremely versatile for many different fabrication and manufacturing processes...
A plastic tank is a large capacity liquid or granular storage unit that can be vertical, horizontal, below or above ground, as well as movable. They are designed to hold several gallons of a variety of substances for long periods without experiencing wear, weathering, or deterioration...
A plastic rod is a solid plastic shape made by the process of plastic extrusion or plastic co-extrusion. These have a contrast of plastic tubing and hollow plastic profiles. Plastic rods are found in various industries, including...
Plastic trim products are extruded linear profiles that can be made to any length. Because of its ability to attach, hold, and seal, plastic trim has many applications. Plastic, HDPE, LDPE, butyrate, PVC, acrylic, and...
A plastic water tank is a large capacity container designed to store water for household, agricultural, irrigation, and industrial manufacturing use. There are various types of water tanks produced to meet the needs of specific applications, with...
A poly tank is a plastic storage tank used to store, transport, and collect water, other liquids, and granular or powder materials. They are made of polyethylene or polypropylene and are a cost effective, lightweight, and easy to handle...
A coupling is a device that is used to transmit power between two shafts connected together at their ends. Couplings serve one primary purpose: to join two pieces of rotating equipment together, while...