How Long Do Hot Melt Hoses Really Last?
One of the most important components in any adhesive dispensing system is the hot melt hose, responsible for transferring the molten adhesive from the tank to the application point or nozzle, at a consistent pressure and temperature. The durability and reliability of this component is essential because hose failure can pose a significant safety hazard to operators and bystanders, as well as cause product wastage and a nightmarish cleanup job that can derail your production schedules. So, how long does – or should – a hot melt hose last under active service conditions?
In this article, we will look at the main factors that determine the lifespan of a hot melt hose, including operational factors, component compatibility, and maintenance practices.
What influences the lifespan of a hot melt hose?
How long an individual hot melt hose lasts is not a fixed duration (despite what some manufacturers might have you believe). A high quality, well maintained, compatible hot melt hose should last 5-7 years, but this figure is heavily influenced by its working environment, usage intensity, and the materials it handles. Leading risk factors include:
Ø Operating temperature: consistently operating a hose at the upper end of its temperature rating will accelerate wear on its internal components, such as the core tubing and wiring. Overheating can cause the inner lining to become brittle and crack, reducing its lifespan.
Ø Adhesive: the chemical formulation of the adhesive you use also has a direct impact. ‘Aggressive’ formulations, and those with a high viscosity, often place greater strain on the hot melt hose core, for instance. Furthermore, adhesives with low thermal stability (such as many cheaper products) can generate more char and other contaminants, leading to blockages and increased internal pressure. It is essential to use compatible hot melt hoses to avoid an adverse reaction to your adhesive formula.
Ø Physical stress: hoses used in robotic applicator arms and other dynamic applications are subject to continual flexing and twisting. This puts mechanical stress on the hose, which can cause fatigue in the electrical wiring and structural layers of the component, sometimes triggering premature failure. Inefficient routing systems that include sharp bends or pinch points can also increase physical stress.
Do not let hoses lay on the factory floor as this will create hot spots and lead to premature failure; hoses can be suspended from the parent machines’ framework or with specially designed hose support hangers.
So, how do you tell if a hot melt hose needs replacement?
The worst thing you can do, in maintenance terms, is to wait until the hose fails before replacing. But nor is it cost-effective to replace components at arbitrary intervals, either, as many businesses that do so end up swapping out perfectly serviceable items, thereby increasing their lifetime cost of ownership. The key to smart replacement is proactive inspections. By identifying the signs of a failing hose, your maintenance teams can plan a tailored service and replacement routine around the specific needs of your production line.
Some of the tell-tale indicators of impending failure include visible exterior wear, especially obvious signs of splitting on the outer protective layer, alongside other signs of abrasion. In fact, any damage to the exterior can compromise the integrity of internal components, and should be taken very seriously. Reduced performance is another indicator, especially inconsistent heating. If certain sections of the hose are cooler than others, it may point to a failure in the heating element wires. This can produce cold spots that can cause the adhesive viscosity to change, increasing the risk of blockages and inconsistent application.
And finally, keep a close eye out for any evidence of adhesive leaking from the hose fittings or body, as this is a critical early sign of failure. If you suspect a leak, the hose should be decommissioned immediately and replaced with a manufacturer-approved component.
Find out more
At Adhesive Laundry, we provide a cleaning, repair, and maintenance service for all leading hot melt adhesive machines, helping improve the reliability and performance of your production line. We also provide a range of hot melt spares - you can browse our range of hot melt spare parts here.
To find out more or to request a quote, please get in touch with one of our team today by calling 01480 271800, or send us a message by clicking here.
