In the world of mobile mining equipment, uptime isn’t just preferred, it’s essential. When a leading OEM for mining machinery sought a new partner capable of mass producing formed tubes and streamlining hose assembly logistics, they turned to Omni Services. What began as a formed tube production solution quickly evolved into a holistic fluid transfer partnership — and at the heart of it all? Hose routing.

Why Hose Routing Matters

Hydraulic hose routing may not be the most glamorous aspect of equipment design, but when it’s done incorrectly, it’s one of the quickest paths to costly downtime and maintenance issues. Proper hose routing protects against:

• Abrasion and wear
• Pressure surges and distortion
• Twisting, kinking, or bending beyond tolerance
• Improper length or unsupported spans
  
  

Let’s put this in context.

The OEM Challenge

The OEM’s initial challenge was finding a partner that could deliver formed tubes at scale for mobile mining equipment. But as the relationship with Omni Services developed, it became clear that a fully integrated approach was needed — not just for tubing, but for the entire fluid transfer system, including hydraulic hoses.

Omni responded by:

• Dedicating production lines to the customer at one of their OEM production facilities
• Adding hose assembly capabilities to their OEM center
• Kitting hose and tube assemblies with custom labeling and tagging
• Setting up on-site hose assembly cells for last-minute modifications and back-up needs

Common Hose Routing Mistakes and How to Avoid Them

Using real-world examples like those from the Hydraulic Hose Routing visual guide, here’s how to spot bad routing — and what to do instead.

1. Too Tight or Too Straight?

• Wrong: No slack in the hose can cause pressure surges to damage the line.
  
  
• Right: Always allow for a loop or gentle bend to accommodate expansion.
  
  

2. Clamping at the Wrong Points

• Wrong: Clamping near bends causes stress and fatigue.
  
  
• Right: Clamp hoses at neutral, straight points for stability.
  
  

3. Twisting the Hose

• Wrong: Twisting causes internal stress and premature failure.
  
  
• Right: Route hoses in a way that avoids rotation, especially during flex.
  
  

4. Bending at Sharp Angles

• Wrong: Sharp bends restrict flow and damage hose walls.
  
  
• Right: Use angle adapters or fittings to preserve flow and bend radius.
  
  

5. Cross-Plane Issues

• Wrong: Forcing a hose across different planes without support causes kinking.
  
  
• Right: Clamp hoses at plane transitions or use two-plane routing solutions.
  
  

Beyond Assembly: The Value of Smart Kitting

Omni didn’t just route and assemble hoses — they kitted them for the OEM’s assembly line, tagged and labeled for plug-and-play installation. That kind of preparation minimizes install time, reduces confusion, and ensures proper hose routing even in complex equipment geometries.

Final Thoughts

Proper hydraulic hose routing is the invisible backbone of reliable machinery. From pressure regulation to component longevity, routing choices impact everything.

This case study shows that when hose routing is handled with expertise, supported by in-house manufacturing and logistics like Omni Services provides, the results speak for themselves: streamlined production, fewer equipment failures, and more confident, efficient builds.

Want help solving your own routing or assembly challenges? Contact Omni Services to talk fluid transfer solutions with a team that knows hose systems inside and out.