Hydraulic hose manufacturing

A hydraulic hose is a flexible hose used in hydraulic systems to transport hydraulic or mineral fluids, fuel, gases, and various emulsions from one point to another. At first glance, a hydraulic hose may appear similar to a garden hose used for watering plants; however, a closer look reveals that the materials and structure of hydraulic hoses are specifically engineered for operation in hydraulic systems.

Much like a garden hose allows water to flow between components, a hydraulic hose ensures the movement of hydraulic fluid between the hydraulic pump and actuator ports, thereby generating mechanical motion. A hydraulic hose functions as a channel that allows fluid to flow without restriction—making it a critical component of hydraulic systems, without which no system operation would be possible.

Hydraulic hoses come in various types but are typically constructed of three layers, which provide durability and resistance to high pressure and temperature. They must also withstand demanding conditions such as abrasion and harsh operating environments. Additionally, hydraulic hoses are frequently subjected to bending and flexing, as they are often installed in areas requiring movement—for example, when transferring the energy needed to lift an excavator bucket.

For this reason, both the manufacturing process and the materials used in hydraulic hose production must meet strict quality standards. Otherwise, system efficiency may be compromised. A damaged hose can pose a serious risk to equipment and machinery, and in some cases, may result in injury to personnel. The quality and reliability of hydraulic hoses and other hydraulic system components are ensured through regular inspection and maintenance.

In general, hydraulic hoses are used across all industrial sectors where pneumatic and hydraulic systems are required, including:

• Construction machinery

• Agricultural equipment

• Mining machinery

• Woodworking machinery

• Aviation industry

• Automotive and railway equipment

• Municipal services

• Pharmaceutical industry

• Logistics sector

• Oil and gas industry

Depending on the type and application of the hydraulic system, the most suitable hydraulic hose must be selected. Choosing an incorrect hose can cause significant damage; therefore, it is essential to evaluate the hose’s properties and advantages carefully. Hydraulic hoses are generally classified into two main categories: those complying with SAE (Society of Automotive Engineers) standards and those complying with EN (European Norm) standards. SAE-compliant hoses are considered industry benchmarks and are widely used in the United Kingdom. The SAE standard covers as many as 16 different hose types, meaning each hose must meet strict dimensional and performance requirements.

Five main types of hydraulic hoses:

• Braided hydraulic hose
  A high-pressure hose typically used with petroleum- or water-based fluids at temperatures ranging from –40 °C to +100 °C. These hoses may be reinforced with one, two, or three layers of steel wire braid and are commonly used in general industrial and power transmission applications.

• Multi-spiral hydraulic hose
  An extremely flexible hose with a special construction, making it ideal for high-impulse applications. Multi-spiral hoses are commonly used for transferring mineral and hydraulic oils, as well as water–oil emulsions. They are widely applied in construction, civil engineering, mining, quarrying, the oil industry, and agriculture.

• Low-pressure hydraulic hose
  A textile-braided hose characterized by high flexibility but not designed for high-pressure use. It is best suited for light-duty applications such as antistatic supply lines, air lines, lubrication systems, and return lines.

• Stainless steel wire braided hydraulic hose
  A highly robust hose reinforced with single or double layers of stainless steel wire braid. This structure provides exceptional reliability and durability, allowing the hose to withstand extreme temperatures and pressures, including vacuum conditions. It is used in aggressive environments where chemical or abrasive media must be conveyed.

• Thermoplastic hydraulic hose
  Manufactured from two layers of thermoplastic material separated by a reinforcing layer made of wire and synthetic fibers. Due to its structure and materials, this hose performs well at very low temperatures and offers excellent resistance to abrasion and wear. Thermoplastic hoses are widely used in hydraulic lifting equipment and, due to their small outer diameter, in lubrication systems.

A wide range of materials is used in the manufacturing of hydraulic hoses, including composites, elastomers, metals, polymers, silicone, and thermoplastics. The choice of materials largely determines the hose’s application, performance characteristics, and compatibility with specific types of hydraulic fluids. Nevertheless, all hydraulic hoses are constructed from three main layers: an inner tube, a reinforcement layer, and an outer cover. Let us examine each of these in more detail:

Inner tube

The inner tube is typically made of plastic or rubber. This layer comes into direct contact with the hydraulic fluid; therefore, its material must be durable and resistant to the specific fluid being conveyed. For example, if a particular fluid degrades rubber, plastic should be used instead. Otherwise, the hose material may react with the fluid or become damaged, potentially leading to failure of the entire hydraulic system.

Reinforcement layer

The reinforcement layer is located between the inner tube and the outer cover and may consist of multiple layers if required, providing increased strength and durability. The flexibility and strength of a hydraulic hose depend on the material used for reinforcement, such as metal, plastic, or textile. The reinforcement method also plays a key role: wire braiding offers greater flexibility but lower strength, while wire spiraling provides higher strength at the expense of flexibility. This reinforcement layer counteracts both internal and external pressure forces.

Outer cover

The outer cover protects the inner tube and reinforcement layers from environmental influences. Extreme temperatures and direct sunlight can accelerate abrasion and wear. The outer cover may be made of plastic, rubber, metal, or textile, depending on the intended application. If the hydraulic hose is used in aggressive environments, it will be manufactured from more robust and resistant materials.

To ensure that hydraulic hoses are of the highest quality, reliable, and ready for their intended application, the manufacturing process must be carried out with great care. Hoses are measured multiple times and thoroughly tested. High-quality production equipment is also essential—such as the MB350 EVO SC 5.5 kW hydraulic hose crimping machine used in our facility.

Typically, the hydraulic hose manufacturing process includes the following steps:

1. The hose is measured.

2. The hose is cut at the marked position.

3. If required, the outer hose layer is stripped.

4. If required, the inner hose layer is stripped.

5. The fitting and coupling components are assembled.

6. The hose is crimped.

7. After crimping, the outer ferrule diameter is checked again.

8. The assembled hydraulic hose is tested.

9. Finally, the hose is cleaned, drained of water, and blown out.

If you are planning to purchase a hydraulic hose, we always recommend consulting a specialist. A professional can determine the most suitable hydraulic hose for your specific needs and calculate the required parameters and performance characteristics. To streamline the selection process, it is advisable to consider several key criteria that will help you choose a hydraulic hose that meets your requirements:

• What type of fluid will flow through the hydraulic hose?

• Under what operating conditions will the hose be used (temperature, pressure)?

• What hose length and diameter are required?

• How flexible and durable should the hose be?

• What type of hose fittings are needed, and where will the hose be connected?

If you still have questions or would like to discuss a solution tailored to your needs, please contact our consultants. Drawing on their experience and expertise, they will help you find the optimal solution. We also provide hydraulic hose crimping services—our mobile and compact hydraulic hose crimping equipment is especially useful in situations where the hose cannot be removed from the machine.