JÄGER Busi­ness Blog

Five things to keep in mind

when it comes to hose assemblies.

12.01.2022   |  Mar­cel Hitze­mann & Steven Bouajila


Secure the Start of Production

Learn which fac­tors influ­ence your SOP!

Along with pipes, hoses are the means of choice when it comes to trans­port­ing liq­uids, solids or gas­es. How­ev­er, hard­ly any pro­duc­tion com­pa­nies think about this top­ic. How­ev­er, there are a num­ber of poten­tials for opti­miza­tion and sources of error in the han­dling of hose lines that deci­sion-mak­ers should be aware of.

Here are five things to consider.

1. The selec­tion of the right hose depends on the con­di­tions of use.

As with oth­er plas­tic and elas­tomer prod­ucts, the appli­ca­tion of a hose design is crit­i­cal. There is a suit­able hose for every sit­u­a­tion. If, on the oth­er hand, com­pa­nies choose the wrong prod­uct or mate­r­i­al, they risk los­ing effi­cien­cy or increas­ing main­te­nance costs — and, in the worst case, risk­ing injury.

In gen­er­al, there are four impor­tant ques­tions that man­u­fac­tur­ing com­pa­nies must answer when choos­ing a hose design:

The pres­sure affects the stress­es to which the hose con­struc­tion is sub­ject­ed on a dai­ly basis. The high­er the pres­sure, the more robust the hose must be. Espe­cial­ly since con­struc­tions that are under high pres­sure always involve risks of injury.

The medi­um to be trans­port­ed pri­mar­i­ly influ­ences the choice of mate­r­i­al. On the one hand, com­pa­nies should ensure that the hose does not become cracked or brit­tle under the influ­ence of the medi­um. This can hap­pen, for exam­ple, with fuels, acids or abra­sive mate­ri­als such as grav­el or sand. The hose mate­r­i­al should there­fore have appro­pri­ate resis­tance. On the oth­er hand, it is par­tic­u­lar­ly impor­tant in the food or drink­ing water sec­tor that the hose line does not con­t­a­m­i­nate the medi­um. Here, com­pa­nies should make sure that the hose has the usu­al cer­ti­fi­ca­tions in their industry.

The oper­at­ing tem­per­a­tures also have an impact on the ser­vice life of a hose design. Tem­per­a­ture extremes or strong fluc­tu­a­tions in par­tic­u­lar can cause a hose to quick­ly become brit­tle. The most impor­tant fac­tors here are the tem­per­a­ture of the medi­um to be trans­port­ed and the ambi­ent tem­per­a­tures of the machine or sys­tem in which the hose is installed.

In addi­tion, there are envi­ron­ment-spe­cif­ic oper­at­ing con­di­tions that can have a stress­ing effect on a hose con­struc­tion. These include UV radi­a­tion and ozone expo­sure, weath­er­ing, and sta­t­ic or mechan­i­cal loads.

2. The fit­tings are just as impor­tant as the hose

The prop­er­ties of a hose con­struc­tion depend not only on the elas­tomer­ic com­po­nents, but also on the fit­tings. Com­pa­nies some­times under­es­ti­mate this fact. They make sure that the hose meets all the appli­ca­tion cri­te­ria, but over­look the met­al com­po­nents. This can affect the entire design.

For exam­ple, the fit­tings must have the same resis­tance to acids, fuels or abra­sive mate­ri­als as the elas­tomer com­po­nents, since they are exposed to iden­ti­cal media. It is also impor­tant to look for mate­ri­als to which rub­ber is native­ly resis­tant, but met­al com­po­nents are not nec­es­sar­i­ly (for exam­ple, water).

 Hose assem­blies in red and blue

Par­tic­u­lar­ly in the food and drink­ing water sec­tors, com­pa­nies should make sure that all com­po­nents of the hose design have the indus­try-stan­dard cer­ti­fi­ca­tions. Oth­er­wise, there is a risk that the design will become unus­able for the appli­ca­tion sce­nario, for exam­ple, if food is con­t­a­m­i­nat­ed by met­als that are harm­ful to health.

3. Safe­ty first

In an indus­tri­al con­text, hose assem­blies often car­ry haz­ardous sub­stances. There­fore, safe­ty aspects have a high pri­or­i­ty. Incor­rect han­dling of hoses not only threat­ens machine break­downs, but also the risk of injury.

High-pres­sure hoses, for exam­ple, can burst or tear out of fit­tings and injure bystanders by whip­ping. Even small cracks or holes pose risks, as flu­ids can escape at high pres­sure and inject harm­ful sub­stances into the skin.

Com­pa­nies can min­i­mize these risks by choos­ing a suit­able elas­tomer. It is also impor­tant to assem­ble the hose design cor­rect­ly, for exam­ple by observ­ing bend­ing radii or avoid­ing tor­sion. When in doubt, it is advis­able to use fit­tings that are resis­tant to tear-out.

Instal­la­tion sit­u­a­tion hose line

Spe­cial atten­tion should be paid to areas of appli­ca­tion where there is a risk of explo­sion. Here, there is a risk of the hose con­struc­tion becom­ing elec­tro­sta­t­i­cal­ly charged and a spark ignit­ing the volatile gas-air mix­ture. The same applies to areas where there is a risk of dust explo­sions (for exam­ple, when pro­cess­ing flour or saw­dust). If the hose con­struc­tion is to be used in an EX zone, it must there­fore be elec­tri­cal­ly con­duc­tive and ground­ed. All com­po­nents of the con­struc­tion should have ATEX cer­ti­fi­ca­tion, both the hose and the fittings.

4. Hose assem­blies should not be approached too late

When cus­tomers con­tact an elas­tomer­ic prod­ucts sup­pli­er for a hose design, their spec­i­fi­ca­tions are often not designed with prac­ti­cal­i­ty. In some cas­es, their design draw­ings pro­vide for con­fig­u­ra­tions that can­not be imple­ment­ed in this form. Exam­ples include bend radii that are too small, min­i­mum lengths that are not met, or a lack of free­dom of move­ment for the hose, which leads to abra­sion. Design errors of this kind usu­al­ly result in a reduced ser­vice life of the hose construction.

For this rea­son, it makes sense to seek ear­ly con­tact with mate­r­i­al experts who have expe­ri­ence with hoses and can pro­vide their exper­tise. It is always eas­i­er to adapt a prod­uct, machine or sys­tem dur­ing the plan­ning phase. On the oth­er hand, once pre-pro­duc­tion has start­ed, the cost of a change increas­es significantly.

5. Don’t invest too much and don’t invest too little

When select­ing a hose design (as in the plas­tics and elas­tomer sec­tor in gen­er­al), two extremes can often be observed. On the one hand, com­pa­nies like to focus on price and always go for the cheap­est option. On the oth­er hand, some deci­sion-mak­ers often think “a lot helps a lot” and go for pre­mi­um prod­ucts. Both approach­es are counterproductive.

Inex­pen­sive hoses real­ize their low price part­ly at the expense of qual­i­ty. They have a short­er ser­vice life and have to be replaced more fre­quent­ly. The ris­ing main­te­nance costs quick­ly put the pur­chase price into per­spec­tive, mak­ing the hose more expen­sive in the long run.

Even pre­mi­um prod­ucts are not always the best choice. Often, com­pa­nies rely on hose assem­blies that far exceed their require­ments, which is reflect­ed in the cost. At the same time, the bet­ter fea­tures don’t nec­es­sar­i­ly pro­vide real added val­ue. For exam­ple, a hose that can with­stand 15 bar has no advan­tage over a hose that can with­stand 10 bar if the com­pa­ny only wants to pump mate­ri­als through it at 8 bar.

There is a hose for every appli­ca­tion. The best way is to choose a prod­uct that meets the spe­cif­ic require­ments, but does­n’t go too far beyond that.


Unfor­tu­nate­ly, there is no such thing as uni­ver­sal­ly applic­a­ble hose assem­blies. Which prod­uct should be used always depends on the con­text. Every com­pa­ny has indi­vid­ual require­ments for a hose design that include finan­cial, tech­ni­cal, process-relat­ed or safe­ty aspects. It is there­fore worth giv­ing the top­ic the atten­tion it deserves.

Den Start of Pro­duc­tion sichern

Erfahren Sie, welche Fak­toren Ihren SOP beeinflussen! 

Author: Mar­cel Hitzemann

Mar­cel Hitze­mann has been work­ing for Jäger since his appren­tice­ship in 2012. The inter­nal sales rep­re­sen­ta­tive answers cus­tomers’ ques­tions about hoses and fittings. 

Author: Steven Bouajila

Steven Boua­ji­la has been work­ing as a mechan­i­cal engi­neer at Jäger since 2011. He is cur­rent­ly respon­si­ble for hose and fit­tings tech­nol­o­gy in the field. 

Jet­zt Beitrag teilen!

Share on facebook
Share on linkedin
Share on telegram
Share on whatsapp
Share on xing
Share on email
Share on facebook
Share on linkedin
Share on xing
Share on email

Covid-19 Contents