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Kompetenz foxiflex

foxiflex gehört mit zu den führenden Herstellern von Spiralschläuchen aus thermoplastischen Kunststoffen oder speziellen Geweben.

Unsere Kompetenz umfasst unser technisches Know-How bei den einzelnen Herstellverfahren, eine umfangreiche Werkstoffkunde und mehr als 20 Jahre Schlaucherfahrung.

Diese Fähigkeiten und Erfahrungen ermöglichen es uns, immer wieder individuelle Schlauchlösungen in einem akzeptablen Preis-/Leistungsverhältnis anzubieten.

Wir verfahren nach dem Prinzip, dass die Anwendung den Schlauchtyp vorgibt und nicht, dass unser umfangreiches Schlauchsortiment den für Sie richtigen Schlauch bestimmt. Wenn ein Standardschlauch nicht vollständig Ihre technischen Anforderungen erfüllt, dann passen wir diesen so an, dass Sie zu 100% zufrieden sind. 

4 Differing Production Methods

We possess an enormous expertise in the various production techniques for making hoses: 

•    The plastic heat welding of hoses (film and extrusion methods)

With aid of the film heat welding process:


With film hoses the metal helix (spring steel wire (1)) is firmly welded between two strips of film (2). Due to this construction the hose is axially very compressible but very convoluted on the inside as the hose material presses inwards. In the case of an outward convolution the air turbulence would be even more extreme.

This construction method is often used for the suction of air or light dust. This hose construction is less suitable for the transport of solids as the media being transported hits against the inner folds and would lead to higher wear and tear. As a rule, we manufacture this hose type with a wall thickness of 0.4 up to 0.55 mm approx.


With the aid of the extrusion process:


The metal helix (spring steel wire (1)) is fused completely both twist and thrust resistant into the hose wall (2 + 3). These hoses have an extremely smooth inner wall (4) and, beyond that, are extremely flexible. This hose construction enables not only a higher pressure resistance but also the transport of solids of all kinds. By means of the smooth inner surface and the chosen raw material, the service life of the hose can be extended several times when compared to conventional hose types.

Hoses with a wall thickness of 0.75 mm up to 3.5 mm are to be found in our range.
 

•    The Clamping of hoses (all Multi hoses)


In this manufacturing process strips of special fabrics are mechanically clamped together. The outer metal helix not only holds the two strips together but also automatically protects the hose wall from damage.

Using this method of manufacturing, particularly hoses with a high thermal resistance can be produced. Temperatures which reach up to +1,000°C are by no means seldom. Heat welding plastics for use at these high thermal specifications is only limitedly possible.

Depending on the requirement profile we can also combine different fabric types to one another (example: interior chemical resistance, exterior high thermal resistance). 

•   Stitching hoses (foxi PVC-Luttenschlauch, foxi Luttenschlauch Temp)


In stitching hoses the metal helix is put onto the outside of the hose wall and there it is fixed into place with an additional scuff protector (2, 3). The hose wall is sewn as well.

In addition to the helix free cuffs at the ends of the hose customers often wish for a so-called end-ring to be fixed (1). This serves to maintain an open transverse section. Of course, we also offer special end-rings so that hoses can be coupled together without having to use a rubber clamp on the exterior.

Using this construction method we can manufacture both blowing and suction hoses up to 900 mm diameter. These hoses portray both an extremely good compressibility and flexibility.  Furthermore, customised solutions are also possible as we can combine different materials and differing helix pitches with one another.
 

•   Vulcanisation of hoses (foxiVulca Neo 1 till foxiVulca Sil 2)


The construction method is similar to the manufacture of rubber hoses. In this process strips of fabric (2) are wound overlapping around a mandrel and fixed into place with an exterior glass fibre cord (3). Depending on the hose type a spring steel helix (1) can be embedded into the hose wall during this process (Neo 2 and Sil 2 types) or else lie exposed (Neo 1 and Sil 1 types). Subsequently the hose is "baked" or rather vulcanised in an oven. Afterwards the fabric layers are firmly bonded to one another.
On the one hand higher pressure resistant high temperature hoses can be made and on the other hand the possibility exists of combining differing materials to meet individual customer requests when using this construction method. 

By means of these 4 manufacturing processes we are able to customise the hose construction to your individual needs. Just as every material type has its advantages and disadvantages, so too does each hose construction also have its advantages and disadvantages. A universal construction type covering all application areas doesn’t exist.

Being that we possess satisfactory competence in all 4 manufacturing processes, you can assume we will always advise you objectively.


Customised Solutions

Practice shows that the proportion of individual hose solutions steadily increases. The reasons are on the one hand growing technical demands. On the other hand we are only too pleased to embrace customer-specific demands and create a technical solution. 

The multiplicity of solutions is very extensive and would definitely exceed the parameters of this article.
Here are just a few examples:

  • Rectangular Suction Hose
    Requirement: flame retardant according to DIN 4102 B1 and rectangular dimensions
  • "Forklift Truck Resistant " Suction Hose
    Requirement: electrically conductive, extremely flexible, tight bending radius and must be so crush-proof, that a forklift truck can drive over it without narrowing the transverse section.
  • Insulating Suction Hose
    Requirement: particular thermal load under observance of a pre-defined heat-coefficient
  • Robot Hose
    Requirement:  protection hose on robots with a defined number of movement cycles

Talk to us and we will try to solve your hose problem!


foxiflex – solution Cost Optimisation Programme

In over 20 "years in hoses" we have continually visited out customers and carried out technical consultations. While doing so we have often found a large number of hoses of varying types which covering similar applications. This is the case both at machinery manufacturers as well as large end-users.

At a large number of customers this rather "colourful" bouquet of hoses grew in the main solely on historical grounds. When there was a hose problem or requirement for a particular application it was solved on a one-off basis. An overall comprehensive solution or even a technical adjustment of the product to the application was as a rule never carried out.

Arising out of this situation we have often been asked by our customers to "take a look" at their other hose applications.

From this we have developed a cost optimisation programme: thefoxfilex -solution Programme.

We carry out a neutral and objective hose analysis. We always do this from the customer’s perspective and also under the aspect of cost-performance analysis.

Your advantages are:

  • As a rule, savings of 30% approx.
  • Transparent account of the hose solutions in conjunction with the applications (statement of all the pros and cons of the individual construction and material types)
  • Clear cost-performance portrayal to assist in your decision-making
  • A consultation without obligation to buy or else be charged   

Talk to us and we will arrange an appointment with you.


Hose DIN Norm

Not only customers like to ask us for advice on hoses. Also expert bodies contact us and request a technical contribution or a concrete appraisement. In one case we were particularly pleased that we could contribute with our knowledge:

In 2011 we were asked by the professional grouping for hose and fittings technology within the Verband Technischer Handel e.V. (VTH) to take part on the committee to produce a DIN norm for spirally wound hoses made from thermoplastic polyurethane (TPU) (www.vth-verband.de.

The VTH had always wanted to have a separate independent DIN-Norm for spirally wound TPU hoses so that products offered were directly comparable from a quality and technical data stand-point. We also welcomed this as the customer would then receive total transparency about the materials employed, along with types of construction. For this very reason we not only participated financially but also worked actively on the norm as a committee member.

Together with other well known hose makers, representatives of the VTH, as well as representatives of the DIN committee, foxiflex worked for years to produce a draft DIN norm for spirally wound TPU hoses which was eventually published in early 2015 and has been, since then, subject to a 3 month appeal period.  The norm should come into force in early 2016 when no considerable changes need to be made.

Although such a DIN standard has existed for other products for many years, it was not a just a matter of course that a DIN norm for spirally wound TPU hoses would be made.

It is with thanks to the endeavours of the steering committee of the professional grouping for hose and fittings technology that such a norm has been created. We would like to take this opportunity to heartily thank the initiators.