+44 121 753 0077Custom Heated Hoses
Built to order in our UK workshop to match your exact mechanical and thermal specs. We manufacture custom flexible heated hoses for everything from high-temperature material lines to precise sample transport systems.
Built Around Your Exact Requirements
The labelled diagram above illustrates the multi-layer construction typical of our flexible heated hoses. However, because no two process setups are identical, we don’t force your application into a rigid “standard” catalogue build. Every component – from internal core materials to outer abrasion protection – is selected based on your specific media, temperature limits, and mechanical demands.
We are committed to continuous engineering development. By actively integrating the latest advancements in thermal insulation, heating element technology, and durable sleeving materials, we ensure your custom heated hose is built to the highest current industry standards.
For any enquiries, call us on +44 121 753 0077 or email sales@flexibleheatedhoses.com
Engineered for Demanding High-Temperature Applications
Off-the-shelf transfer hoses simply aren’t built to survive continuous thermal cycling, aggressive chemical exposure, and constant flexing. Standard lines often suffer from internal core degradation, wire fatigue, or thermal loss that forces your controllers to work twice as hard. We construct our high-temperature flexible hoses using heavy-duty PTFE or stainless-steel cores wrapped in precision heating elements and multi-layered glass-fibre insulation. This keeps heat directed inward toward your process fluid while keeping external touch temperatures safe for operators.
Because every unit is manufactured in-house, you don’t need to adapt your machinery to suit a restrictive catalogue range. We routinely duplicate obsolete OEM hoses, adjust power ratings to fit site electrical supplies, and build multi-core assemblies that combine heated fluid transport with extra sensor lines and auxiliary wiring in a single, neat bundle.
Built for Performance, Thermal Efficiency, and Reliability
Standard transfer lines often suffer from thermal loss at the couplings, causing material thick spots, pressure drops, and unnecessary energy consumption. Our custom flexible heated hoses are engineered with continuous heating elements that run right up to the swaged end fittings, ensuring total thermal stability and zero cold-spot transfer along the entire working length of the line.
To minimize operating costs, each assembly is wrapped in high-density, multi-layer glass fibre insulation. This thermal barrier locks heat inside the core, significantly reducing electrical power draw while keeping external touch temperatures safe for operators. Combined with robust inner cores and stainless-steel wire braiding, our hoses absorb continuous mechanical vibration, high operating pressures, and frequent bending without structural fatigue or wire failure.
Because every unit is built in our UK workshop, we can re-engineer worn-out or obsolete hoses from foreign equipment manufacturers with fast turnaround times. We also offer bespoke multi-core builds – bundling power cables, temperature sensors, and extra air or fluid lines into a single, streamlined outer sleeve to simplify machine cable management on your shop floor.
Can you manufacture custom heated hoses to match an existing OEM pattern?
Yes. If you have an existing or obsolete hose from a foreign equipment manufacturer, we can build a direct replacement. Provide us with the total length, bore size, operating voltage, sensor type, and thread fittings – or ship the old hose to our UK workshop for direct replication.
What voltages can you build for?
We manufacture hoses for standard 110V site transformers, 230V single-phase supplies, and 400V 3-phase industrial power connections depending on hose length and wattage requirements.
Can these hoses be used in ATEX / hazardous areas?
Yes. We offer specialized heating elements and sealed terminal connections specifically rated for ATEX and IECEx explosive atmosphere zones. Let us know your Zone classification during your enquiry so we can build to specification.
Can custom heated hoses be used outdoors or in high-moisture environments?
Yes. For outdoor installations, wash-down areas, or high-humidity plants, we build hoses with moisture-sealed silicone rubber heating elements and heavy-duty, weather-resistant outer sleeving (such as heat-shrinkable PVC/polyolefin or silicone-coated fiberglass). We also fit moulded silicone rubber end caps exclusively at both ends to seal the internal heating elements and wiring junction against moisture ingress.
What is the minimum bend radius for a custom flexible heated hose?
Minimum bend radius depends on the internal bore size, pressure rating, and outer diameter of the assembly. As a general rule, standard flexible heated hoses require a bend radius between 200mm and 400mm to avoid crimping the internal heating element or restricting fluid flow. If your application involves tight machine clearances or continuous robotic movement, let us know during design so we can specify high-flex cores and strain-relief sleeves.
Can your heated hoses be connected directly to our existing temperature controllers?
Yes. We configure every hose’s power wiring and temperature sensor (PT100, Type J, or Type K) to match your existing control panel, PID controller, or third-party hot melt machine setup. We can also supply standard industrial multi-pin electrical connectors (such as Harting or Amphenol plugs) so your team can plug the hose directly into your equipment without rewiring.
What happens if a heated hose experiences a severe pressure spike?
Every hose build is engineered with a high safety factor above its maximum working pressure rating. Our high-pressure lines feature multi-layered stainless steel wire braiding over the inner core (such as PTFE or smooth-bore steel) to absorb hydraulic or pneumatic pressure surges. We clearly specify both working pressure and burst pressure ratings during the quotation stage to ensure total operating safety.
What is the typical lead time for a bespoke custom heated hose build?
Because we manufacture every hose in-house at our UK workshop, standard custom builds are typically dispatched within 1 to 2 weeks following technical spec approval. If you face an emergency breakdown or an operational line shutdown, we also offer expedited production options to get replacement hoses built and shipped as quickly as possible.
Technical Specifications
- Length: Manufactured to your precise dimensions, from short 0.5m jumpers to long-run transfer lines.
- Bore Sizes: Internal diameters sized specifically to balance fluid velocity, pressure drop, and volumetric flow requirements.
- Pressure Ratings: Engineered for low-pressure gas sampling up to high-pressure fluid delivery systems.
- End Fittings: Swaged terminations in stainless steel, brass, or mild steel across standard and bespoke thread profiles.
- Temperature Sensors: Integrated PT100 (RTD), Type J, Type K, or specialist thermocouples positioned for precise controller feedback.
- Heating Element: Moisture-sealed silicone rubber insulated elements. Certified ATEX / hazardous area builds available upon request
- Thermal Insulation: High-density, multi-layer glass fibre insulation that minimizes thermal radiation loss and reduces power consumption.
- Outer Sleeve: Heavy-duty black polyamide sleeve braiding for mechanical abrasion resistance, or smooth wash-down heat-shrink sleeving for cleanrooms.
- End Caps: Moulded silicone rubber caps fitted exclusively to ensure robust moisture sealing and strain relief at critical flex points.
- Voltage Options: Built for 110V site transformers, standard 230V mains, or 400V 3-phase industrial power systems.
- Control Extras: Auxiliary wiring, pneumatic lines, or supplementary tubes incorporated directly into the internal build to power auxiliary equipment.
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In Business for
over 30 years.
In Business for over 30 years.
