A more efficient method to make hose kits
Wondering if anyone can help? We are a small manufacturer and during our busy season we will make a significant number of hose kits. These are simply 12 foot lengths of pvc braid reinforced hose with hose barb fittings in both ends and aluminum ferrules crimped to retain the hose barbs, then the hoses are 'rolled up' into a roughly 10" circle and taped to retain. It is all done 'by hand' and not very efficiently or repeatable. We have a big 1500 ft spool on a rack. We pull off the hose to a mark on the floor and cut a bunch of 12 ft lengths, one at a time, and just drop them on the floor. Then, we grab one, insert the fitting and put the ferrule on, then crimp it with a hand operated crimper mounted to the wall. The crimper has no stops, so the insertion of the fitting is a careful, eyeballed affair that occasionally leaves a sharp edge. Then, we 'coil' them up to a 'comfortable' diameter and tape them once with black electrical tape in one area to keep them from unraveling.
1. I am thinking that the measuring (from the supply spool) and the end coiling process could be combined. ie. the measuring could be from one large supply spool onto a 'measuring' spool where the hose is then cut and secured with two cable ties and becomes ready for end insertion.
2. Is there a good way to 'apply' the cable ties? ie. with a machine or a technique that makes it easier? (i am thinking at a minimum that the measuring spool might have a couple of dimples in it that would allow for an easy insertion of a cable tie under/around the coil.
3. if the coil is wrapped so that each end is 'available', then the hose barbs and the ferrules can be inserted and crimped while the hose is coiled.
4. an pneumatic crimper would be better, are these available?