How Hydralectric Manufactures Over 2 Million Metres of Braided Hose a Year

When it comes to flexible hoses, what’s on the inside is just as important as the protective braid on the outside. At Hydralectric, making perfect braided hose is a 24/7 operation that relies on premium materials and precision engineering.

It all starts on the inside

Choosing the right liner

It all starts with our core liners, these are matched to the end client requirements from a range of synthetic elastomers, EPDM, TPM elastomers, Ultra low density polyethylene, and PTFE. The liners are typically sourced from our partners in the EU and under strict quality controls, making it compliant with global drinking water directives.

Adding the protective outer layer

To create the protective outer layer, we use premium stainless steel wire,  grade EN. 1.4301(AISI 304) or we use a polyethylene terephthalate (PET) braided applications where metal is not suitable.

From bulk spools to braiding machines

The manufacturing process begins by transferring this wire from large bulk spools onto smaller precision wound spools that fit our range of horizontal axis braiding machines, with either 24, 32, or 48 carriers. Depending on the hose size and required braid pattern, each machine utilises a specific number of spools.

Why braiding takes time

When you look inside one of these machines, you’ll see the spools spinning at an incredibly fast rate. However, the intricate over-and-under weaving process means the actual output can be less than half a metre per minute. Because of this meticulous, slow-yield process, our machines run day and night to keep up with demand.

What 2 million metres a year looks like

Thanks to this continuous operation, we manufacture over 2,000,000 metres of braided hose every single year in various lengths, sizes, and liner materials. While the majority of this goes directly into our own premium hose assemblies, the sheer scale of our UK operation ensures we can meet any application requirement our customers bring to us.