The Hose Station: Making your own hydraulic hose assemblies

Downtime causes stress. Every minute costs money. Waiting for spare parts holds up operations. Makeshift solutions put people and the environment at risk. HANSA‑FLEX’s newly developed mobile hose station enables companies to produce hydraulic hose assemblies themselves, anytime and anywhere.

The hose station contains everything needed for professional hose manufacturing in accordance with DIN EN ISO standards, all housed in a single container. All that is required is a mains power supply or a generator. A particularly clever feature is that the side panel can be folded up to provide cover when working outdoors. A simple tent or tarpaulin provides optional additional weather protection. Thanks to its compact dimensions of just 122 x 360 x 240 cm, it takes up more than two-thirds less space than conventional 20-foot workshop containers, which require around 15 m² of floor space.

“The Hose Station is a genuine innovation in the hydraulics industry. It complements our comprehensive service portfolio, which ranges from the mobile services of the Hydraulic Emergency Service through industrial services for scheduled operations to large service containers. The Hose Station is recommended for all situations where a large service container is not cost-effective or simply not feasible due to space constraints,” explains Christian Falkner, Service Manager for Service Containers at HANSA‑FLEX.

The hose station is suitable both for permanent, stationary use in companies that require in-house hose production, and for short-term, mobile use on construction sites or in industrial applications. In addition to industry and OEMs, its main areas of application include construction, equipment hire and agriculture. “When every minute counts, the mobile hose station is a decisive competitive advantage. A faulty hose assembly can bring entire processes to a standstill and cause high downtime costs,” says Falkner, summing up the time savings. As customers can now manufacture hose pipes themselves on site, downtime is reduced as much as possible and costly transport routes are eliminated. Companies can also flexibly schedule preventive hose replacements. Customers require appropriate hydraulic knowledge to assemble hose lines. HANSA‑FLEX specialists provide the necessary training. 

When equipping the station, Christian Falkner’s service container team drew on their many years of experience with mobile workshops. Despite the compact dimensions, customers do not have to compromise on quality. They receive a tested system that enables the standard-compliant manufacture and marking of hose pipes up to DN 25. All components meet the strict HANSA‑FLEX standards. In addition, customers benefit from a warranty on all machines for the entire service life. The hose station is always equipped via a HANSA-FLEX branch.

All containers are equipped with:

• P20NMS hose crimping machine with 120 tonnes of crimping force, up to SEA100R15 1" – DN25 
• T275 hose cutting machine (3.8 kW, cutting capacity up to DN50) 
• MD2E peeling machine (external peeling DN6 to DN25, internal peeling DN16 to DN25) 
• Hose cleaning system including portable compressor 
• Embossing machine for DIN/EN/ISO crimp sleeve marking 
• Drawer cabinets (1150 mm high, 8 drawers, space for approx. 300 items of material) 
• Workbench with cutting rail, tape measure and retractable vice 
• Pinboard for production and work instructions 
• Auxiliary tools such as callipers, soft-face hammer 
• Manufactured in accordance with applicable DIN/EN/ISO standards and guidelines

Thanks to their compact dimensions, HANSA‑FLEX hose stations are particularly recommended for construction sites or other locations with limited space, where conventional service containers are too large. On-site transport is carried out either by forklift or crane. The station is equipped with forklift pockets and lifting eyes on the roof for this purpose. “When developing the hose station, we placed great emphasis on ensuring that it could be easily transported on a lorry with a loading crane. Our customers can quickly and easily move the hose station exactly where it is needed: right next to the machinery and equipment,” reports Falkner.

The hose stations offer businesses maximum flexibility and process reliability for assembling hose lines on site. The stations are available to hire, and customers can easily tailor the hire period to the duration of their construction projects. A trial period is available, as is hire purchase. The new offering is also economically attractive: there is no minimum turnover requirement and no initial investment is needed. At the same time, customers of the hose stations receive full access to proven HANSA‑FLEX services such as training and support from HANSA‑FLEX experts, or the simple reordering of materials via Scan-to-Order.

Valuable time savings thanks to rapid on-site hose manufacturing, lower costs due to reduced downtime, easy transport and the ability to work on the move even in confined spaces: the HANSA‑FLEX Hose Station sets new standards and opens up new possibilities for companies across a wide range of industries. When used as a stationary unit, the station offers the flexibility of in-house production. “With the new hose station, we are responding to our customers’ desire to be able to manufacture hose pipelines themselves in certain situations. Combining this with other offerings from our product and service portfolio enables us to provide a comprehensive solution to meet customer-specific requirements,” concludes Falkner.