Why Choosing the Right Hydraulic Hose Matters
Selecting the wrong hydraulic hose is one of the most common causes of system failure, unplanned downtime, and — in serious cases — injury. With hundreds of hose types on the market, it can be difficult to know where to start. This guide cuts through the complexity and gives you a practical framework for getting it right every time.
Understanding Hydraulic Hose Types
Different applications demand different hose constructions. Here's an overview of the most common types:
PTFE Hoses
PTFE (polytetrafluoroethylene) hoses are the go-to choice when chemical resistance and high-temperature performance are priorities. The smooth PTFE bore reduces fluid friction, making them ideal for pharmaceutical, chemical processing, and certain food industry applications. They are compatible with virtually all hydraulic fluids and can handle temperatures from -65°C to +260°C.
Food Grade Hoses
For food processing, beverage production, or any application where the hydraulic fluid may come into contact with consumables, food grade hoses are essential. These hoses meet FDA and EU food safety regulations, using materials that are non-toxic and easy to clean. Never use a standard industrial hose in a food-contact environment.
High-Pressure Hoses
High-pressure hoses — typically rated to 350 bar and above — are constructed with multiple wire braid or spiral reinforcement layers. They are the backbone of most heavy plant machinery, excavators, agricultural equipment, and industrial hydraulic systems. The construction method directly determines the maximum working pressure.
Low-Pressure Hoses
Not every application requires high-pressure capability. Return lines, suction lines, and drain lines operate at much lower pressures, and using an oversized high-pressure hose here adds unnecessary cost. Low-pressure hoses, often with textile reinforcement, offer the flexibility needed in these areas at a lower price point.
Working Pressure vs Burst Pressure: What's the Difference?
These two terms cause a lot of confusion. Here's what you need to know:
- Working Pressure (Maximum Operating Pressure): The maximum pressure at which the hose is rated to operate safely and continuously. Never exceed this in normal operation.
- Burst Pressure: The pressure at which the hose will fail. Burst pressure is typically 4:1 over working pressure — meaning a hose rated at 300 bar should burst at around 1,200 bar. This safety factor is built in, but it is not a licence to exceed working pressure.
Always specify hose with a working pressure rating above your system's maximum operating pressure, and account for any pressure spikes or transients your system might produce.
Temperature Ratings
Temperature has a significant impact on hose life and performance. Every hose has a rated temperature range covering both the fluid temperature and the ambient (external) temperature. Key points to consider:
- Continuous high-temperature operation degrades the inner tube and outer cover more quickly.
- Cold temperatures can make hoses stiff and brittle — important in outdoor applications in winter.
- PTFE hoses offer the widest temperature range; standard rubber hoses are more limited.
Always check the temperature rating of your chosen hose against your system's actual operating conditions, not just nominal conditions.
Fluid Compatibility
Not all hoses are compatible with all hydraulic fluids. The inner tube material must be chemically compatible with the fluid being conveyed. Using an incompatible fluid can cause the inner tube to swell, deteriorate, or shed particles into the system — contaminating your oil and potentially damaging pumps, valves, and cylinders.
Common hydraulic fluids and typical inner tube compatibility:
- Mineral oil: Compatible with most rubber and PTFE hoses.
- HFA/HFB/HFC water-based fluids: Require specific inner tube materials; check the manufacturer's compatibility chart.
- Phosphate ester (HFD): Requires PTFE or specially rated hoses.
- Biodegradable fluids (HETG, HEES): Compatible with most rubber hoses but confirm with the supplier.
The STAMPED Method
A useful memory aid for specifying hoses is STAMPED:
- S – Size (bore diameter)
- T – Temperature (fluid and ambient)
- A – Application (what is the hose doing?)
- M – Material compatibility (fluid type)
- P – Pressure (working and peak)
- E – Ends / fittings (connection types)
- D – Delivery / routing (bend radius, routing constraints)
Build Your Own Hose Assembly
At Hydra-Line, we make it easy to get a hose assembly built exactly to your specification. Use our Build Your Own Hose tool to select your hose type, length, and end fittings. We cut and crimp hose assemblies to order with fast turnaround.
Need Expert Help?
If you're unsure which hose is right for your application, our technical team is here to help. We've been supplying hydraulic hoses to UK industry for years and can advise on the right product for even the most demanding applications.
Call us on 01782 658535 or email info@hydra-line.co.uk — we're always happy to assist.