Views: 266 Author: Sunmoon Publish Time: 2022-01-20 Origin: Site
Discover how Sunmoon Hose successfully navigated the complex engineering challenges involved in manufacturing 20-inch TPU layflat hoses. This case study details our entire process—from sample approval to the bulk shipment and delivery of hoses for a major water supply project in Southeast Asia—fully demonstrating our expertise in providing industrial-grade hose solutions.
In 2021, the global market for ultra-large diameter TPU layflat hoses was limited, with few manufacturers capable of producing 20-inch hoses while maintaining stable, high-performance quality. Unlike smaller, standard-diameter hoses, scaling up to a 20-inch diameter is not a simple linear process. It requires a fundamental re-engineering of the reinforcement structure, rigorous dimensional stability controls, enhanced pressure resistance, and unwavering production consistency.
Our client required a robust solution for a long-distance, high-volume water transfer infrastructure project. The technical specifications were demanding:
●Diameter: 20 inches
●Working Pressure: 6 bar (90 psi)
●Burst Pressure: Exceeding 20 bar (300 psi)
●Primary Application: Critical, high-volume industrial water delivery
At Sunmoon Hose, we approach every project with an "engineering-first" mindset. Scaling production to this magnitude presented four critical challenges that required our technical expertise to solve:
●Dimensional Stability: Maintaining exact hose diameter during the high-pressure production curing process and subsequent operational deployment is difficult due to the massive physical volume of the hose.
●Structural Reinforcement: Ensuring uniform reinforcement strength across the entire, expansive hose body is essential to prevent localized weak points.
●Bonding Integrity: Achieving consistent, high-strength bonding between the TPU layers and the inner reinforcement fabric under large-scale conditions is paramount for durability.
●Field Deployment Logistics: A 20-inch hose is heavy and cumbersome. We had to ensure the final product was practical for real-world transport, rapid installation, and efficient deployment in rugged, off-road environments.
Our solution followed a meticulous, data-driven production lifecycle, ensuring that the final bulk delivery met the exact performance requirements established during the initial design phase.
We initiated the project by manufacturing and delivering prototype samples to the client for comprehensive field evaluation. This crucial phase allowed the client to test the hose under actual site conditions, confirming that our design successfully addressed their unique operational challenges.
Before moving to bulk manufacturing, every component passed our proprietary factory testing protocol. Key highlights of our quality assurance process included:
●Hydrostatic Pressure Testing: Each assembly was subjected to rigorous stress tests to confirm performance.
●Verification Protocols: We consistently tested at 1.5 times the rated working pressure to guarantee a high safety factor.
●Integrated Solutions: Testing included the full hose-and-coupling assembly, ensuring 3 hours of continuous operation under pressure to verify structural integrity and leakage prevention.
Following successful client approval and validation, Sunmoon Hose commenced large-scale production. The first milestone delivery consisted of:
●Logistics: Two 40HQ containers packed with approximately 2,000 meters of hose per container.
●Destination: Southeast Asia, designated for a massive infrastructure water transfer site.
●Project Continuity: This shipment served as the successful opening batch for a larger, multi-phase project, establishing a reliable supply chain for ongoing operational requirements.
This case study demonstrates our core competencies in engineering, manufacturing, and global project management. We provide more than just catalog products; we deliver verified, performance-tested solutions for the most demanding applications in the oil, gas, construction, and agricultural sectors.
When you partner with Sunmoon Hose, you gain access to:
●Proven Manufacturing Capability: Experience producing ultra-large diameter TPU, NBR, and PVC layflat hoses (2" to 20").
●End-to-End Project Support: Expert assistance from technical specification and sample approval to bulk production and international logistics.
●Unwavering Quality: Reliable pressure testing protocols ensuring structural integrity in field deployments.
For large-diameter water transfer projects, precision matters. We do not just list 20" hoses in a catalog—we manufacture, test, and ship them globally to meet your exact technical specifications.
SUNMOON HOSE
TPU | NBR | PVC Layflat Hose Manufacturer
Diameter Range: 2" – 20"
Custom pressure • structure • length • couplings
www.sunmoonhose.com
WhatsApp: +86 18857413937
