Choosing the right option for emergency replacement of hydraulic hoses and couplings is essential to minimise costly downtime in the case of leaks or system failure.

In this situation, plant engineers still have three options; use a local specialist, a mobile van service or install a DIY/self assembly facility. However, changes in working practices, developments in jointing technology and recent broadening of available equipment ranges have changed what might be the right choice both in terms of reliability and overall cost effectiveness.

One of the first things to consider is the size of a site and the average number of failures experienced in a month.

Many smaller manufacturers with relatively few failures (less than five per year) often rely on outside companies who specialise in hydraulic hose assembly as a quick and reasonably cost effective method.

However, this solution still relies on an in-house engineer physically taking the hose to a specialist and waiting for a new assembly to be produced, a process that can still take up valuable time even if the order is sent ahead of delivery.

It is worth noting that a plant operating 24hrs a day can incur extra costs when repairs have to be completed outside working hours.

For companies that have similar numbers of failures and have multi-site facilities or are in remote locations, the preferred solution is the mobile van service.

The mobile option is ideal for quarries and other processing industries as it is a speedy solution that does not rely on in-house engineers and supplies all the necessary stock and equipment.

Call out charges are substantial for the service however, and there is always a chance that the van is not immediately available, the correct components are not on board or the fitting requires more pressure than a mobile crimper can provide.

Larger companies with in-house tool shops have traditionally relied on their own engineers to complete the repair and therefore significantly reduce the downtime caused by hydraulic failure.

In the past, this option has been ignored by small to medium sized companies due to the high cost of crimping machines, stock carrying and training requirements.

However, companies are now realising that the amount of replenishable stock required to account for all eventualities, can in fact be relatively small and, the next generation of crimping machines include smaller and less costly models, making them a far more attractive proposition.

Despite large industrial suppliers providing both on and off site hydraulic repairs, many of these companies believe that self-assembly is the way forward and have responded by supplying a budget range of mobile manual crimping machines designed for maintenance operations and small production runs.

For as little as GBP 1200, companies can now purchase tailored self-assembly kits which consist of a manual crimper, a selection of couplings and up to six hose sizes that allows any employee to produce new hoses covering most applications.

By following the simple step by step instructions provided, staff can produce a factory-quality hose assembly in under five minutes, which is less time than it would take to order a new one from a third party supplier.

When compared to the cost of mobile suppliers, the complete set up can pay for itself in as little as five failures.

For medium volume production runs across the entire hose range, larger stationary crimpers are also available at more accessible prices, with models designed for hoses of a higher-pressure range and providing reliable operation in the toughest field applications.

In the past many companies have experienced failures after in-house repairs due to the fact that the range of hosing and couplings available were often not of a high enough quality.

In contrast, quick fit coupling designs are now available that avoid the need to remove the hose cover or lining (skiving) and are made from one cast piece of material rather than brazed construction, eliminating the common causes of failure.

The hose itself has also undergone price changes and offers an improved construction with the most recent designs providing higher resistance to external oil and grease and protection against abrasion, even where dirt is attracted to the lubricants.

To ensure that the correct stock is always at hand, accounts can be set up with the larger industrial suppliers such as Wyko who, thanks to their unique partnership with Gates can deliver their high quality replenishment hosing and couplings stock anywhere in the UK, 24 hours a day.

Wyko provide replenishment stock on a next day basis as standard, allowing companies to reduce inventory without the risk of extending downtime.

When combined with a policy of standardisation on the size of terminations and the use of inexpensive adapters across a site, this can greatly reduce stock levels and costs.

In addition to the crimping machines and components, a full range of workshop equipment to speed up the crimping operation is also available, including rotational tables for unwinding hose coils, storage cabinets, hose cutting and pressure testing machinery.