Hose Assembly Installation Guide: How to Change a Hose Correctly

Forget lightbulbs – how many people does it take to change a hose - properly?

You've invested in the best equipment, your business is underpinned by high standards, your staff are experienced, and your customers expect nothing less than excellence. Perfect! However, sometimes, even in the largest establishments and most professional environments, it's often the smallest task that carries the biggest risk - especially when it's performed incorrectly.

One of the most common culprits is hose assembly installation and replacement, which should be treated as a priority during equipment training or onboarding.

It's often overlooked as it's seen as a simple task, even intuitive, that anyone can do with a few 'lefty loosey, righty tighty' turns of a wrench. The truth is, without proper training, changing a hose can quickly turn a routine install into a costly and avoidable failure.

At Flextech, we have seen first-hand how critical correct hose installation is across a wide range of sectors, from food and drink to pharmaceutical, and chemical to industrial sectors. In industries where precision, compliance, and safety are non-negotiable, they depend on correct installations as it's a corner that can't be cut.

So, let's demystify the attaching process and equip you and your team with the knowledge to do the job safely and effectively, first time, every time.

Hose Assembly Installation Is a Process, Not a Swap

Whether you are replacing a worn hose or fitting a brand-new assembly, the procedure matters. A hose is a vital component in manufacturing which, if fitted incorrectly, can lead to a plethora of issues - some immediate and others hidden until it's devastatingly too late.

Before installing, inspect the new equipment thoroughly, looking for any signs of visible damage that might have happened in transit. Ensure the hose is the correct one you ordered and suitable for the job in hand.

Even the best quality hose can fail if it's not properly selected for the required job. If it's exposed to the wrong temperatures, pressures or media, it won't perform as expected and could pose serious safety risks.

Why You Should Never Reuse Hose End Fittings

Re-ending or reusing hose fittings is never advisable, as it jeopardises the safety and integrity of the hose assembly. This approach can result in connection failures, leaks, or even severe accidents due to weakened or improperly fitted components. Additionally, it voids the manufacturer's responsibility, meaning any subsequent issues are the sole responsibility of the installer. Although some companies may promote this as a way to cut costs and gain business, it is neither a safe nor acceptable practice.

Always buy new, industry-approved correct fittings to ensure that each hose complies with the necessary safety standards.

Using the Right Tools for Hose Fitting

You need to get the right tool for the job. Don't improvise. You need to use properly sized equipment that won't damage the fittings or cause incorrect force or trauma while fitting. Also, you should avoid excessive twisting and turning, as this can impact the fitting and the hose, weakening the structures and shortening its lifespan.

Give the hose itself love and affection, too. Ensure that there aren't any bends or kinks and avoid contact with abrasive surfaces. Reducing strain gives your hose the best possible chance of its full intended lifespan.

Pressure Testing Your Hose Assembly After Installation

A newly installed hose assembly must always be pressure tested in a controlled environment before being used. This vital step helps verify that the setup is not leaking, structurally sound, and is safe for use during operation. Skipping this is not an option, it's a serious part of the process, and if it's not carried out, it's a recipe for disaster. If you try to bake a cake without an oven - it won't turn out right. This won't either.

In addition to performing the test, the results should also be recorded. It's best practice to do so through documentation as it forms part of the quality assurance process and provides traceability in the event of any incidents. Maintaining these records demonstrates a commitment to safety and compliance, protecting the operator and operation from liability.

Hose Assembly Maintenance: Protecting Your Investment

Once you've successfully installed your new fittings, the work is still not complete. Proper maintenance is still required to ensure that hose assemblies, fittings and connections continue to perform safely and effectively. Regular inspections should be part of the routine, checking for signs of wear and tear, kinks and leaks that could compromise your system.

By prioritising ongoing maintenance alongside correct industrial hose installation, you extend the lifespan of your assembly and protect your product, equipment, staff, customers, and reputation. This approach also helps reduce unnecessary risk or unexpected financial outgoings or losses, ensuring smooth and safe operations over the long term.

The Risks of Incorrect Hose Installation

So, what's the impact and true extent of getting an installation wrong? It goes further than just an inconvenient leak or two; it can lead to serious safety issues and inconvenience, including:

• Contamination of products in hygienic manufacturing areas such as food and pharmaceuticals
• Equipment failure due to backed-up pressure or crushed hoses
• Unwanted downtime hinders production, creates export delays, and results in financial losses
• Personal injury from slipping on leaked substances or skin contact with hazardous or hot media
• Environmental harm from escaped toxic materials that can contaminate the likes of water supplies, leading to regulatory fines
• Damage to a brand's reputation and lack of customer trust

Perhaps the most concerning thing is that these issues often aren't immediately apparent. Many start as small-scale, undetected faults that accrue over time, but with proper installation, testing, and maintenance, could have been avoided.

Shining a Light on Installation

We have all heard the old joke, "How many people does it take to change a lightbulb?" Maybe it's time that was updated because, based on what we have seen in the field over the years, a surprising number of people still don't know how to change a hose correctly. And unlike the original lightbulb joke, that's no laughing matter.

When you next need a new assembly, please visit our hose solutions page for all your hose solutions.