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In process plants where hoses are a critical part of production, regular replacement and maintenance are an integral part of operations. In practice, it is typically only the hose itself that wears out due to process influences such as heat, pressure and cleaning. Nevertheless, many choose to replace the entire hose solution – even if the nuts and hose tails are still fully functional. This results in unnecessary expenses, higher maintenance costs and unnecessary strain on resources.
With our reassembly service, we reuse nuts and hose tails and only replace the worn parts. This provides a solution with the same operational reliability, hygiene and documentation as a new one – but at a significantly lower price.
Read on and learn about the benefits!
When hoses wear faster than couplings
Hoses in the food industry and the pharmaceutical industry are exposed to heavy loads in the process line on a daily basis: high temperatures, CIP cleaning, chemical influences and pressure variations. Over time, this weakens the durability of the hose.
In some production processes, there are additional influences. In dairies, for example, it often happens that hoses are damaged by daily collisions with trolleys and equipment. This can significantly shorten the service life of the hose, even if the coupling parts are still in good condition.
Even under demanding conditions such as these, the coupling parts often prove to be more resistant than the hose itself. Nuts and hose tails are made of stainless steel and can withstand both pressure and temperature without losing their tightness or strength. Nevertheless, the entire unit is often replaced at each service interval – typically because it is perceived as the easiest solution. But this is an expensive habit. Every time you do this, you discard components that could easily have lasted for many more years.
How the reassembly process works
With our reassembly service, you get a hose solution that combines cost-effectiveness with high-quality and proven reliability. The aim is to ensure that you get the most out of your existing components without compromising on functionality or safety.
The process is straightforward and starts right there in your production facility. You remove the used hose from the system and assess whether your hose tail connectors and bushings can be reused. As a starting point, you cut off the hose couplings and send them to us. From there, we take over the process and carry out the reassembly quickly and efficiently.
The rest of the process takes place at our assembly workshop and comprises four careful steps:
1. Assessment
When we receive your hose tails and nuts, we assess their condition. We check whether they have the necessary quality to be used in a new hose solution.
2. Technical inspection
We test the components for tightness, mechanical strength and hygiene standard. If they show signs of corrosion, wear or deterioration, they are discarded. Only components that meet the requirements proceed to the next step.
3. Assembly
We assemble the approved components on a new hose with new bushings. Any discarded components are replaced with new ones. Our fitters work in accordance with current standards for pressure, hygiene and mechanical stability. Each hose is pressed, tested and finished with the same precision as a brand new hose solution.
4. Pressure testing and documentation
Finally, we carry out a quality check to document that the finished hose solution meets all technical and safety requirements. Each coupling is given a batch number for full traceability. On request, we can also pressure test the hose and issue a certificate.
The result is a hose solution that works like new in practice. You get the same quality, the same documentation and the same operational reliability as with a completely new hose, but with savings of up to 60%.
Reassembly pays off
Is the saving real? Yes – and it can be felt directly in the operating budget.
Let's take a realistic example from the food industry:
A company that produces oil-based sauces uses the following hose solution:
- Hose length: 2 metres
- Hose dimension: 2″
- Hose type: Oily Food SPL
- Coupling type: DS union nut, 90° elbow
The hose is exposed daily to CIP with high temperatures and alkaline cleaning agents. This causes continuous wear on the hose section, while the couplings remain in good condition.
Instead of replacing the hose and couplings at each service interval, the company opts for reassembly: only the worn hose and sockets are replaced, while the hose tail and nuts are reused.
With a hose solution like this, the company achieves a saving of 57.48% per hose without compromising on functionality, operational reliability or documentation.
In short, your company can benefit from a number of advantages:
- Same hygiene and safety
Refurbished hoses come with full documentation and traceability, so each component can be traced back to production. You get the same quality and operational reliability – just at a lower price.
- Less resource consumption
Only the worn hose section is replaced, while the studs and nuts are reused. This reduces your material consumption and provides a more sustainable solution, where you get more value from your existing components. - Better operating economy
The lower replacement price reduces your maintenance costs and frees up funds for other improvements in your production.
Get advice on the most advantageous solution
Reassembly is suitable for many hoses, but not necessarily all. That is why we offer expert advice based on your hose specifications, media conditions and cleaning routines. Every day, our specialists advise on which hoses are suitable for reassembly and how you can plan replacements without unnecessary downtime.
If you have any questions or need clarification about the potential for reuse in your process line, help is at hand. Contact us by phone on +45 7020 0422 or by email at inquiry@alfotech.eu.