Pneumatic hoses are susceptible to various issues, including kinking, leaking, cracking, and potential bursting. These complications may arise from several factors, such as substandard quality, blockages, environmental conditions, and inappropriate operating temperature or pressure within the pneumatic system.
Leaking or bursting pneumatic hoses can lead to significant downtime and increased production costs. If these issues are not promptly addressed, maintenance expenses can skyrocket, impacting the company’s financial health.
As reported by the U.S. Department of Energy, a compressed air leak measuring as small as 1/4 inch (6.35 mm) can lead to an annual increase in production costs of up to $38,776, which equates to approximately IDR 600 million.
Therefore, it is crucial to be vigilant about pneumatic hose issues, as they are vital for achieving optimal efficiency in modern industrial Pneumatic Systems.
In this article, the expert team at Bawalaksana Central Industrial will outline the common causes of pneumatic hose damage and leakage and provide recommendations to prevent hoses from kinking, leaking, or bursting.
The Causes of Kinking and Leakage in Pneumatic Hoses
Pneumatic hoses are prone to kinking and leakage primarily due to their limited capacity to endure the heat and pressure generated by the system. This is particularly evident when the materials or specifications are incompatible with the specific industrial application.
The following are some of the most prevalent factors contributing to the occurrence of kinking, cracking, or bursting in pneumatic hoses:
Over-Reliance on Vendors
Industrial organizations frequently adopt a comprehensive procurement strategy when implementing pneumatic systems and procuring devices and components from a single vendor, including pneumatic hoses.
This procurement approach offers various benefits, such as enhanced time efficiency, consolidated pricing, streamlined delivery, and simplified implementation. The organization effectively receives all necessary components under one invoice.
However, alongside these advantages arise unforeseen challenges, including the risk of acquiring hoses of subpar or inadequate quality. This could lead to more frequent replacements, increased downtime, and potential safety hazards.
Industrial teams may need more time and resources to conduct thorough research to select the appropriate type of hoses, particularly for specialized industrial applications across sectors such as petrochemicals, food and beverage, or electronic manufacturing.
Consequently, these teams may opt for the standard hoses provided within the vendor’s pneumatic and automation packages.
Due to economic considerations, organizations may refrain from substituting vendor-supplied hoses with higher-quality alternatives to avoid administrative complexities or complications with equipment warranties.
Over time, the performance of these vendor-supplied hoses may deteriorate, exhibiting signs of weakness and frequent failure, which ultimately undermines the company’s productivity.
This results in recurrent issues associated with pneumatic hoses, including cracking, kinking, or bursting—challenges that become routine concerns. If left unaddressed, these issues can lead to increased downtime, interrupted maintenance operations, and potential safety risks.
Meanwhile, frequent hose replacements necessitate increased machinery downtime, interrupting necessary maintenance operations.
Therefore, consider a scenario in which production demand is at its highest, and deadlines are imminent. Such circumstances can lead to significant frustration, do they not?
Recommendations
If you have encountered the abovementioned issues or wish to mitigate their impact on your company, consider exploring alternative, high-quality pneumatic tubing solutions.
This approach will enable you to secure durable, premium hoses that align with the specifications and requirements of your industrial applications.
We recommend contacting authorized industrial hose distributors to request product samples, which will allow you to assess the quality of their offerings.
Subpar Quality of Tubing Materials
Industrial-grade pneumatic tubing comprises materials and formulations that differ significantly from those utilized in conventional or household hoses. Although the primary materials—such as Polyamide (PA), Polyurethane (PU), Polyethylene (PE), Polyvinyl Chloride (PVC), Teflon, or silicone—may be similar, notable quality disparities arise when these materials are employed in industrial applications.
For instance, while various PVC hoses are currently available in the market, the quality of these products can vary markedly based on the manufacturer.
This principle similarly applies to industrial pneumatic hoses, as different manufacturers adhere to distinct quality standards. Additionally, variations in material composition, design, and certifications exist among these hoses.
Research and Development teams at industrial tubing manufacturers must conduct thorough investigations before establishing their products’ composition, design, and dimensions. This comprehensive process necessitates significant time and financial investment.
Nevertheless, such efforts culminate in the production of high-quality hoses that satisfy the increasing demands of contemporary industries.
If a hose’s material composition and formulation are not sufficiently optimized, it may result in a product of inferior quality. Substandard hoses cannot endure the rigorous operational demands in actual industrial environments, leading to issues such as kinking, cracking, or bursting within a short operational timeframe.
Recommendations
It is essential to select hose materials that correspond with the specific requirements of your industrial application. This knowledge empowers you to make informed decisions that can significantly impact the performance of your pneumatic system:
- Polyamide (PA): This material is ideal for general industrial and automotive applications.
- Polyurethane (PU): This material is ideal for applications requiring high mobility, such as those involving industrial robots.
- Polyethylene (PE) or Fluoropolymer: These materials are suitable for applications that involve exposure to chemicals and high temperatures.
Given the extensive range of industrial hose options and sizes available, it is advisable to consult with experts to identify the most appropriate type for your specific application.
Improper Use of Specifications
It is essential to recognize that manufacturers’ specifications of industrial hoses are meticulously defined and limited in their applicability. Each type of hose is designed for specific industrial applications and is not intended for general-purpose use. Consequently, selecting the appropriate industrial hose to match your specific application is paramount.
To assist in identifying the correct type of industrial hose, consider addressing the following inquiries:
- What is the operating pressure?
- What are the environmental conditions? Is there potential exposure to UV radiation, humidity, or elevated temperatures?
- What fluid will flow through the hose (e.g., air, oil, chemicals, corrosive gases, ozone, grease, or lubricants)?
- In what context will the hose be utilized? Is it for mobile applications like low/high movement robots or static installations?
- Will the hose come into direct contact with food products?
- Are there combinations of high pressure, high temperature, chemicals, and extreme environmental conditions?
Addressing these questions can ascertain the appropriate hose specifications that align with real-world conditions, material requirements, and industry standards.
Selecting the correct hose can enhance system efficiency, boost productivity, and optimize overall investment costs. Should you require further assistance in identifying a suitable solution for your company’s specific applications, you are encouraged to consult the expert team at Bawalaksana at no cost.
Excessive Pressure
Industrial pneumatic tubing generally possesses a safety factor ratio ranging from 3:1 to 4:1 concerning the working pressure at a standard temperature of 23°C. This indicates that the hose may rupture or burst when subjected to pressures exceeding three to four times the maximum recommended limits at this temperature.
As operating temperatures increase, the maximum working pressure the hose can endure diminishes correspondingly. Each hose type presents a distinct graph illustrating its working pressure capabilities, a resource included in the user manual provided by the manufacturer of the industrial tubing.
The accompanying graph demonstrates a sample pressure drop scenario for Teflon (PTFE) tubing sourced from Mebra Plastik Italia, a recognized manufacturer of industrial tubing.
A significant contributor to pneumatic hose failure is the failure to adjust air pressure following the manufacturer’s pressure drop graph. Therefore, it is imperative to align the choice of industrial tubing with the specific application requirements in the field. It is advisable to select tubing that can adequately withstand the system’s operational pressure demands.
Proactive Measures
Utilize the pressure values recommended by the manufacturer, as outlined in the provided graph, to ensure optimal durability and performance of the hoses. For instance, a Teflon hose with an inner diameter of 10 mm can sustain a pressure of 6 BAR (87 Psi) at 23°C.
According to the graph, assuming a safety factor of 3:1 for Teflon tubing, the maximum pressure the hose can withstand at 200°C is 1.2 BAR (17 Psi). It is critical to avoid applying pressures that exceed twice the recommended limits.
Common Causes of Excessive Air Pressure in Pneumatic Systems
- Improper adjustment of the filter, regulator, and lubricator (FRL) unit
- Undetected failures in pneumatic system components
- Inadequate lubrication of pneumatic cylinders or valves
- Clogged exhaust lines
By addressing these factors, one can significantly enhance the reliability and efficiency of pneumatic systems.
Recommendations
Conduct daily inspections to ensure that pneumatic tubing remains in optimal condition. It is essential to replace pneumatic tubing promptly before any leaks or ruptures occur.
Utilize pneumatic hoses following their specified industrial guidelines, ensuring that the system operates within the temperature and pressure parameters recommended by the tubing manufacturer, as indicated by the pressure drop graph.
When the manufacturer does not provide a pressure drop graph, it becomes challenging to mitigate the risks of potential leaks or cracks within the hose.
Regular maintenance of the FRL unit, cylinders, and pneumatic valves is imperative to prevent the accumulation of dirt and dust, which can obstruct the airways. This preventative measure assists in avoiding blockages that may lead to excessive air pressure.
Environmental Factors Affecting Industrial Hoses
Environmental conditions can substantially influence the degradation of industrial hoses, leading to brittleness, cracking, or significant damage.
In fact, industrial tubing failure is not instantaneous but a gradual degradation, wear, and weathering process. Over time, these factors contribute to the material’s rigidity, loss of elasticity, and, ultimately, cracking or bursting.
Several environmental factors may exacerbate the wear and deterioration of industrial tubing, including:
- Prolonged exposure to extreme temperatures
- Accumulation of oil and dirt contamination that remains unaddressed
- Exposure to chemicals or corrosive gases that exceed product specifications
- Repeated sterilization, mainly if the tubing material is not inert
- High humidity and susceptibility to microbial attacks
- Friction with adjacent objects
- Excessive pressure
- Exposure to sparks
- High mobility applications
- Ultraviolet (UV) radiation
One of the primary challenges for pneumatic systems is the accumulation of moisture and water within the hose. If these conditions are not managed, they may increase brittleness and a higher likelihood of hose failure, particularly in products with high hygroscopic properties, such as low-quality nylon or polyurethane hoses. (Read: How to Properly Drain Air from Pneumatic Systems and Understand Its Importance)
The hygroscopic nature of specific hoses can adversely affect their dimensional stability and increase permeability, compromising airtightness. This leads to tubing expansion, loss of integrity, wear, and failure stemming from air moisture exposure.
Pneumatic tubing is susceptible to premature failure under continuous exposure to extreme environmental conditions. As the hose’s performance declines, it becomes increasingly vulnerable to kinking, cracking, and bursting sooner than anticipated.
Additionally, the nature of the fluid conveyed through the hose significantly impacts its lifespan, especially when dealing with aggressive chemicals, corrosive gases, gasoline, or applications that involve high-mobility robots.
A Reliable Solution
Mebra Plastik Italia, a prominent manufacturer located in Italy, provides practical solutions for complex challenges encountered in various industrial applications. Their extensive range of industrial tubing options encompasses the following:
- Systems for pressurized air or vacuum in pneumatic applications
- Tubing suitable for ATEX environments, sensitive to static electricity
- Solutions designed for welding environments exhibiting resistance to spark exposure
- Tubing for the transportation of oil, grease, and lubricants
- Applications involving steam for petrochemical industries or power generation
- Transfer of aggressive chemicals or corrosive gases
- Solutions for food-grade and drinking water contact
- Equipment for disinfestation and nebulization
- Components for air shafts and clutch systems
- Systems designed for powder paint applications
- Solutions for industrial automation
- Tubing for raw material granule loading
- Cable protection mechanisms for energy chains or carriers
- And numerous additional applications
The company can significantly enhance productivity and system uptime by selecting high-quality, industrial-grade hoses tailored to its unique industrial needs. This strategic choice can also significantly reduce production downtime and maintenance costs, improving operational efficiency.
Installation Errors in Industrial Tubing
A prevalent cause of failure in industrial tubing is improper installation, which significantly diminishes the tubing’s operational lifespan. Below are several common installation errors that may lead to damage:
- Utilization of fittings and connectors that do not adhere to the manufacturer’s specifications.
- Incorrectly securing or positioning the tubing can lead to excessive friction, bending, or tension.
- The tubing length is insufficient for applications that require high mobility, which can result in stretching, stress, or compression.
- The selection of industrial hoses with an inappropriate bending radius for specific applications renders them susceptible to kinking and cracking.
- Using rigid tubing in high-mobility situations can easily cause the hose to crack and be damaged.
- Using flexible tubing in high-pressure or high-temperature environments can cause the hose to stretch and break easily.
- Use of non-black tubing in applications exposed to high UV levels, contrary to manufacturer guidelines.
- Using highly hygroscopic tubing in uncontrolled or high-humidity environments leads to rapid dimensional changes, stretching, and increased breakage risk.
Recommendations
To mitigate these issues, it is imperative to utilize fittings and connectors that align with the manufacturer’s specifications for industrial tubing. Adhering to these recommendations can prevent leaks and damage at the connection points. While reducing tubing length may decrease potential pressure drops within the system, excessively short tubing can introduce unnecessary tension and stress.
Matching the tubing type to the specific demands of the application is crucial, especially in extreme environments or cases requiring high mobility. Consulting with experts or sales engineers is advisable to identify the most suitable tubing for critical applications.
By ensuring proper installation and selecting the appropriate tubing for operational requirements, your company can enhance system efficiency and substantially prolong the tubing’s lifespan.
Final Thoughts
Numerous factors contribute to companies’ industrial hoses or tubing challenges, including leakage, cracking, kinking, and bursting.
In light of our discussion regarding the susceptibility of pneumatic hoses to leakage and bursting, we draw the following conclusions:
- Material Does Not Guarantee Durability: Although industrial hoses may be constructed from similar materials by different vendors, their durability can vary when subjected to industrial conditions.
- Moisture Impact: Humidity levels can affect hoses’ dimensional stability and lifespan. Hydrolysis-resistant tubing should be utilized in applications operating in damp environments.
- Graph of Pressure Drop: This serves as a crucial reference point to prevent hose failure due to inconsistencies in pressure.
- Proper Installation: Adherence to best practices in installation can effectively mitigate the likelihood of kinking and leaks.
As advised by the engineering team at Bawalaksana, comprehensive research and analysis are imperative before procuring industrial hoses. If necessary, obtain samples from authorized distributors for pneumatic and industrial tubing intended for use.
This approach will enable you to:
- Ensure the acquisition of high-quality hoses that are suited to demanding applications.
- Directly compare hose performance under real-world conditions.
In contemporary manufacturing, professionals recognize that the success of pneumatic systems is closely linked to mobility, energy efficiency, and maintaining high standards for industrial tubing.
Consequently, it is critical to exercise discernment when selecting industrial spare parts, including pneumatic components and hoses. By doing so, your company can attain regulatory compliance, enhance cost efficiency, and sustain high productivity levels.
Preventing Downtime with High-Quality Pneumatic Solutions
This article discusses the importance of understanding the various causes of pneumatic hose cracking and bursting to proactively prevent unexpected downtime and the associated increase in production costs.
PT Bawalaksana Central Industrial is an authorized distributor of Mebra Plastik Italia’s pneumatic hoses and industrial tubing. Our organization is dedicated to assisting your company in selecting and supplying high-quality industrial hoses that meet international certification standards.
Additionally, we are the official distributor of pneumatic components and systems from Metal Work Pneumatic, a brand renowned for its high performance and efficiency.
For over five decades, Mebra Plastik and Metal Work have been at the forefront of pneumatic technologies and modern industrial automation systems, earning the trust of multinational corporations around the globe.
By utilizing superior-quality hoses and highly efficient automation systems, your operations can achieve optimal productivity, facilitating the transition to a smart and modern Industry 4.0.
If you consider implementing advanced pneumatic systems with enhanced efficiency, you have come to the right place.
PT Bawalaksana Central Industrial can assist you in either implementing modern pneumatic systems or upgrading to the latest automation technology suited for your organization.
We encourage you to discuss your requirements with our Sales Engineering Team to receive the most suitable recommendations for your business. Please click the consultation button below to initiate a discussion with our professionals.
Romanta Pinrih Linuwih
Pneumatic Automation Systems Expert
This article was written in collaboration with Romanta Pinrih Linuwih, an expert in Pneumatic Automation Systems, to ensure accuracy and high quality.
