HYDRAULIKPRESSE april 2009, english issue - Hansa Flex

Issue 02/2009 

HydrAuLikPreSSe 

MAGAZINE FOr cuStOMErS ANd EMPLOyEES OF tHE HANSA-FLEX GrOuP OF cOMPANIES 

INDUSTRIAL HOSES FOR 

SPECIAL APPLICATIONS 

11 

DESIGNING PIPES 

CORRECTLY 

20 

HANSA-FLEX SOLUTIONS 

LOWER COSTS 

22 

It needn't end in tears 

2-zeilige Headline 

hier eingeben 

Dolor ad magniam digna ad tet dunt lor sit 

lam, quat velesto coreet la ad tat. Ut volestrud 

dolore ming el ut aci blaore modolore esto 

duisim del diamet, sed dolendigna feugueros 

nulpute dolorpe raestrud molestrud eui tat. 

Rit wiscin utatie volese consequam in eugiam 

elit do eumsandio eriliquat. Dunt aliquat nulla 

conummy nonsequ issenit la consectem 

veniatue velesed doloreet nostinim vullaor 

inciniamet, con vulputat auguero odit ad 

magna feum ipis num dunt nullan ullan ulla 

core er irilla feugue minciduis alisit adionsed 

ting eraeseq uiscil ip erat volore ming el ea 

feumsan hent nosto conse conse dolobor. 

Function and protection of our most important sensory organ 

HYDrauLiKPresse 04|2009

CoNteNt HydrAuLIKPrESSE 04|2009 

03 editoriAL | iMPreSS 

04 iNduStriAL ServiCe – PreveNtAtive MAiNteNANCe 

New lifeblood for the gigantic track construction machine "rM 800" 

09 NeW At HANSA-FLeX: "iNduStry uNd MobiL ServiCe" 

Hydraulic Solutions - the hare beats the tortoise 

industrial service: 

overhauling a giant 

A quick look at looking 

04 

industrial hoses: All fluid 

10 

lines from a single source 

Practical: 

20 

designing pipelines correctly 

24 

Aircondition-Hoses 

28 

from HANSA-FLeX 

Photo: Julia Ahlers Photo: Julia Ahlers 

Photo: Julia Ahlers Photo: Jens Frommann Photo: Julia Ahlers 

10 iNduStriAL HoSeS FroM StoCk-oN-HANd 

All fluid lines from a single source 

11 A SPeCiALity AMoNG SPeCiALiStS 

Industrial hoses on the high seas 

12 Not A "9-to-5" job 

On the road with Gudrun dittrich, field technician 

14 tiMe For tHe riGHt CAreer StArt 

Professionals at HANSA-FLEX have many opportunities 

15 trAiNiNG SeMiNAr SCHeduLe oF tHe iHA – APriL/MAi 

16 XWorLd iN SiberiA 

In the footsteps of "the courier of the tsar" 

18 AN eye For tHe eSSeNtiALS 

Preventing machine stoppages and accidents 

20 At Work: HydrAuLiC LiNe eQuiPMeNt 

designing pipelines correctly lowers operating costs 

22 HANSA-FLeX SoLutioNS 

Lower costs, raise performance – HANSA-FLEX Solutions can do that 

24 Work & LiFe: A QuiCk Look At LookiNG 

Eyes are fascinating sensory organs, and it is important to protect them 

26 SoLutioNS: iN Good SHAPe For tiGHt SPotS 

Preformed hoses and bent pipes for special cases 

28 AirCoNditioN: keeP CooL WHeN tHiNGS HeAt uP 

the fast hose for a healthy atmosphere 

30 tHe 38tH vdbuM-SeMiNAr iN brAuNLAGe 

HANSA-FLEX sponsors seminar and offers XWOrLd adventure as drawing prize 

31 QuiZ | FACtS & FiGureS | PrevieW 

02 

HANSA-FLEX customers magazin

IMPrESS editoriAL 

deAr reAderS, 

Perhaps you were as surprised at the appearance of the last issue of HydrAuLIKPrESSE as the young 

man pictured on the cover. Leafing through its pages, you would certainly have noticed immediately: 

your magazine has changed, both visually and with regard to content. this relaunch, as the 

experts call such phenomena, is reflected in the appearance of the magazine, but equally in its 

layout and material. the HANSA-FLEX website had a graphic make-over as well and has now a more 

contemporary appearance. Shortly more language will be added – currently the site is available in 

German and English – which enables finally just one international website in the medium-term. 

the new HydrAuLIKPrESSE has room for big stories, with a generous format that does justice to 

the text and illustrations, and also for short hints and informational contributions on all aspects of 

fluid technology. At the same time, we venture beyond the strict limits of our business and draw our 

readers’ attention to topics that are not directly related to hydraulics. For example, in this edition we 

open your eyes to one of our most important sensory organs – the eye! 

editor / PubLiSHer: 

HANSA-FLeX Hydraulik GmbH 

Zum Panrepel 44 · 28307 bremen 

Phone: 0421 - 48 90 70 

telefax: 0421 - 4 89 07 48 

e-Mail: info@hansa-flex.com 

www.hansa-flex.com 

you should take a close look at the article on “Industry and Mobile Services” in this issue of 

HydrAuLIKPrESSE. the article provides an introduction to this line of business, recently offered by 

HANSA-FLEX. In these economically tense times, as our industry is intensifying its efforts to optimise 

its cost centres, we offer our customers a service package that includes all of our capabilities and offers 

new options. With Industry and Mobile Services we are combining all our former activities in the 

areas of FLEXXPrESS, Industry Service, Hydraulics Workshop and Fluid Services. With these service 

offerings, we are addressing our customers’ requirements directly and taking industrial service 

into new dimensions. On page 9 of this issue you can read a detailed account of the way this new 

business division is expected to evolve, as envisaged by its new chief dieter Hohnen. customised 

concepts of this kind strengthen our customers’ value added chain and are integral to our mission 

to conquer the market with services designed to optimise the benefit to our customers. Service 

modules such as “kanban and consignment warehouses”, “kitting” and the “plant-in-plant” have 

shown potential for cutting OEM costs and increasing output. these service offerings are described 

in greater detail on page 22. 

you can also find out about the new solutions that HANSA-FLEX will introduce at the Hannover trade 

fair beginning on April 20, 2009. We look forward to meeting you then, at stand d 30, hall 21. 

Compilation: enrico kieschnick, Horst otto 

(PAPP Werbeagentur) 

Layout: jan-Christoph Fritz, Nadine beneke 

Print: berlin druck · www.berlindruck.de 

responsible for contents: Wolfgang rink 

Frequency: bimonthly 

Subscribe to the HydrAuLikPreSSe on our website. 

PeFC/04-31-0976 ivW certified 1st quarter 2008 

iSSue FebruAry 2009 

15th volume 

Photo on front page: julia Ahlers 

Photo: Julia Ahlers 

tHe eXeCutive MANAGeMeNt 

dieter H. Seidler, uwe buschmann, thomas Armerding 

HYDrauLiKPresse 04|2009 03

At Work Industrial service 

Not your everyday job: working on the RM 800 was 

something quite different. Since very few design drawings 

existed, it was not even possible to give more than rough 

estimate of the scope of the job. Hundreds of hose lines, 

threaded connections,valves and seals had to be replaced. 


04 


INduStrIAL SErvIcE At Work 

PreVentatIVe maIntenance 

NEW LIFEBLOOd FOr tHE GIGANtIc trAcK cONStructION MAcHINE "rM 800" 

After 20 years of gruelling service on the railways of the republic, it has happened at last: the rM 800 has been given a new circulatory 

system as part of a major overhaul. It was time to carry out a complete replacement of all the hydraulic hose lines on this gigantic yellow 

track construction machine. A complex job, like a jigsaw puzzle, which HANSA-FLEX was tasked with solving. 

the JH construction company was founded in 

1905 by master builder Joseph Hubert and 

is headquartered in Nuremberg; it specialises 

in track construction and maintenance. In 1956, 

J. Hubert introduced the first self-propelled tamping 

machine and has been a respected partner to 

deutsche Bahn as well as private and municipal 

transport companies for decades. By the 1960s, JH's 

fleet included 14 track tamping machines; these are 

now supported by specialist machines using the latest 

technologies, so that all track construction work 

can be carried out without any loss of continuity. 

One of the jewels of this collection is the rM 800, a 

high-performance monster for cleaning the track 

bed. the machine is 76.5 

metres long, and performs 

several functions in a single 

pass. First it raises the 

track, for which a hydraulic 

superelevation compensator 

in the arc ensures 

a gentle bending line for 

the raised track segment. then, an excavating chain 

passes underneath the track and collects the ballast. 

the ballast is transported on conveyor belts to two 

vibrating screens in the front part of the fully hydraulically 

operated machine. the heart of the rM 800 

is the screening car, with its two separate eccentric 

vibrating screens and slewing spoil transfer conveyor 

belt. the spoil is separated from the ballast in the 

screen units, and the cleaned ballast is then returned 

to the track bed via conveyor belts in front of the 

rear bogie of the excavating car. then, the tracks are 

automatically lowered back into place. When operations 

are running smoothly, the machine is capable 

of cleaning about 2000 metres of track bed in a shift 

of about 9 hours. 

SkiLL ANd CoordiNAtioN 

Of course, the railway operators have to harmonise 

their timetables with the operation of the track bed 

cleaning machine, so work can often only be carried 

out on weekdays, holidays, or at night. Accordingly, 

"No other service provider 

in Germany had the capability 

to support us so completely!" 

there is only a very narrow window of opportunity 

for carrying out the work, because the track construction 

vehicle must be removed from the lines 

used by IcEs and freight trains in good time. In practical 

terms, this means that the machine must be 

working reliably at all times; there is absolutely no 

time for interruptions, unplanned repairs or, heaven 

forbid, a complete breakdown. So the track construction 

machine undergoes preventative maintenance 

at strictly fixed intervals. And after 20 years of operation, 

it was finally time for the rM 800 to undergo a 

thorough overhaul. 

As part of this, all of its hydraulic hose lines were 

replaced, together with everything associated with 

them. A highly complex 

task, which posed stringent 

requirements both in terms 

of the skills of a crack team 

of specialist fitters and 

with regard to delivering 

hose equipment, fittings 

and threaded connectors 

on time. therefore, J. Hubert turned to HANSA-FLEX, 

since as a system partner the group possesses both 

the industrial skills and a network large enough and 

flexible enough to meet their needs. 

Field technician Joachim Brock has looked after the 

J. Hubert account for the last five years from the 

HANSA-FLEX Nürnberg-Nord agency, which is headed 

by regional manager Frank dahms. Originally, he 

serviced their hydraulic needs associated with the 

depot in Fürth. their work on lorries and excavators 

convinced depot master Peter Münch, who knows 

this hydraulics service provider to be a reliable, professional 

partner. For dieter Brauer, the service manager 

for track construction machinery at J. Hubert, 

this was an important factor in his decision to award 

the order to HANSA-FLEX. 

After that, everything happened very quickly. But 

we will let Joachim Brock tell the story in his own 

words: "In October 2008, the customer inquired as 

to whether we could take this job on. Well, the first 

Photo: J. Huber co. 



tHe CoLoSSAL, HiGH PerForMANCe rM 800 carries out 

all the tasks that are involved in track bed cleaning one after 

the other: it raises the track, picks up the ballast, removes 

the spoil and returns the ballast to the track bed before 

placing the track back in position – it can clean up to 2000 

metres of track per day. 

HYDrauLiKPresse 04|2009 05

At WOrk Industrial service 

THE 76.5 METRE LONG RM 800 was brought into the 

Deutsche Plasser sheds for refurbishment. The entire hydraulic 

system, as well as other systems, had to be completely 

overhauled. A team of technicians from HANSA-FLEX, the 

J. Huber company and Deutsche Plasser was put together, 

and they worked together closely and enthusiastically. 


thing we had to do was decide on the scope of the 

job together with the managers at J. Hubert and 

Plasser & Theurer." This was no easy task for Joachim 

Brock, because there are only a limited number of 

engineering drawings showing the exact layout of 

the hydraulic circuits; moreover, each track construction 

machine is modified in accordance with the customer's 

wishes. "And since a lot is hidden from view 

by cladding, we were only able to make an approximate 

estimate of the scope of work. At all events, the 

work involved hundreds of hose lines and threaded 

connectors, replacement of valves, and probably the 

rapid repair of hydraulic cylinders and supply of new 

seal kits. So we already knew that HANSA-FLEX was 

probably the only company that was really capable of 

fulfilling this order." 

Start on time 

The order was awarded on December 19, 2008, "and 

punctually on January 7, 2009 the personnel were 

ready at the vehicle workshop of the manufacturer 

Plasser & Theurer in Buchloe to make the best use of 

the tight timeframe for the first phase of the overhaul 

under the direction of workshop supervisor 

Roland Weiß." During this time, they first carried 

out all the work that was needed on the machine's 

undercarriage. For this, the huge track construction 

machine was brought to Buchloe and placed on 

supports in a shed. "All of the bogies and units were 

removed from the frame to make enough room so 

that we could even get at the hydraulic elements. 

Only then could we start specifying the hose lines, 

note their exact positions, and remove them to produce 

a new part before fitting everything back in." 

There was certainly plenty to do for all the hydraulic 

THE FIRST PHASE OF THE PROJECT was taken up with 

simply exposing the hydraulic connecting elements – for this 

the machine had to be placed on supports and much of its 

internal equipment was removed. 


experts who designed the hose lines under Joachim 

Brock's leadership. All of the manufacturer's hoses 

had to be transcoded to HANSA-FLEX products, and 

the mining hoses that had been used previously had 

to be replaced with new materials, which meant that 

different external diameters had to be considered. 

This in turn affected the fixing equipment, which 

meant that approvals for the pulse frequency and 

pressure loads had to be taken into account. 

The HANSA-FLEX industrial fitter team was supported 

by the four J. Hubert machine operators. Thomas 

Schulz, Volker Schenzel, Ralf Heinrich and Jose Guinarte 

know their track construction vehicle intimately 

from years of experience. They were able to provide 

useful advice to ensure that work advanced at 

a brisk pace. On this basis, the industrial fitter team 

from Dresden, managed by project engineer Dirk 

Symossek, were able to continue their work without 

losing any time. During the overhaul, Sven Nagel, 

Patrick Goebel, Olaf Fischer and Manuela Ohun were 

tasked with completely renovating the hydraulic 

connecting elements. And since the industrial fitters 

had brought their complete workshop with them, 

they were also able to remove and install hydraulic 

cylinders and provide rapid assistance through the 

HANSA-FLEX cylinder repair and seal production 

business units. 

06 

HANSA-FLEX Customers magazin



"The fact that there is a HANSA-FLEX agency 

so close makes it possible for us to obtain 

replacement parts without delay, and if necessary 

even to call out service personnel!" 


At the same time, the HANSA-FLEX engineering and 

plant construction (EAB) business unit was also on 

standby throughout the overhaul, because the machine 

was disassembled so that all the components 

could be inspected. then if defects were discovered in 

the valves or pumps, certified engineer Wolf-dieter 

Letsch of EAB was tasked with designing the replacement 

part and delivering it immediately. 

HuNdredS oF HoSe LiNeS had to be replaced. they were 

all supplied with an X-Code to minimise stoppages in the 

event that repairs are needed in future. 


the industrial fitter team was supported in terms 

of daily logistics by the HANSA-FLEX agency in 

Augsburg. Agency head thomas Karg arranged the 

scheduled supply of hoses, fittings and threaded connectors. 

"that is the great advantage of our tightly 

interwoven agency network," explains Joachim 

Brock, "because a HANSA-FLEX agency is always 

close by, we are able to obtain replacement parts 

without delay at all times, and if necessary we can 

also mobilise service personnel in support of the industrial 

fitter team." 

the personnel from the industrial fitter team even 

accompanied the machine during field commissioning, 

just in case. this way, they were ready to respond 

promptly and appropriately if any leaks occurred. 

FLeXXPreSS joiNS iN 

"We figured FLEXXPrESS into the job from the outset, 

and we drafted it in such a way that not only would 

the fitters from dresden accompany the commissioning 

phase for the track construction train, but 

a FLEXXPrESS service vehicle would also be in attendance. 

In this way, we could ensure that a fully 

equipped workshop with all the necessary parts for 

producing hose lines would be readily available," 

Joachim Brock points out a special feature of the job. 

The order 

in overview 

The task 

Overhaul hydraulic connecting elements on 

the RM 800 track bed cleaning machine 

The timeline 

• Inquiry from J. Hubert in October 2008 

• Order received by HANSA-FLEX on December 

19, 2008 

• Start of work: January 7, 2009 in the 

construction sheds of Deutsche Plasser in 

Buchloe/Allgäu 

• Commissioning following overhaul: March 

2009 

The service 

Companies involved: 

• HANSA-FLEX branch office in Nuremberg, 

Project Management 

• HANSA-FLEX industrial assembly, Dresden 

• HANSA-FLEX branch office, Augsburg 

On standby: 

• HANSA-FLEX engineering and plant construction 

(EAB), Dresden-Weixdorf 

• HANSA-FLEX sealing technology, Königshofen 

• HANSA-FLEX hydraulic cylinder repair, 

Königshofen 

• FLEXXPRESS 

HYDrauLiKPresse 04|2009 

07

At work Industrial service 


Replacement part 

procurement optimised 

with X-CODE 

As of now, X-CODE is also travelling on RM 800, because 

all hose lines were identified with X-CODE during 

the overhaul, so that J. Hubert can take advantage 

of the fastest replacement part service on the 

market. If a fault occurs in one of the hose lines on 

the machine later while it is in service anywhere in 

the Federal Republic, the necessary replacement part 

can be obtained and installed quickly and surely. 

Because there is always a HANSA-FLEX agency or a 

FLEXXPRESS close by – wherever the train is. 

The successful, smooth fulfilment of the order served 

as justification after the fact of the decision to award 

the contract to HANSA-FLEX, because the system 

partner was served well by its ability to immediately 

deliver hydraulic hoses with widely differing 

specifications, fittings and threaded connectors, 

and of course by the presence of an agency in the 

vicinity of the installation site. "This entire package 

impressed us," says Dieter Brauer, "no other service 

provider in Germany was capable of supporting us so 

thoroughly during this short preliminary and implementation 

period. Because the operating schedule 

for the machine is fixed, it has to be ready to start 

again on time. Even the courtesy and congeniality of 

HANSA-FLEX employees were essential to the successful 

completion of this order, because the overhaul 

required the simultaneous involvement of many 

third-party companies. Our decision for HANSA-FLEX 

was absolutely the right one!" 


WORKING SHOULDER TO SHOULDER from l. to r. Sven 

Nagel (HANSA-FLEX, lead fitter), Olaf Fischer (HANSA-FLEX, 

fitter), Dirk Symossek (HANSA-FLEX, project engineer), 

Manuela Okun (HANSA-FLEX, fitter), Roland Weiß 

(Deutsche Plasser, master mechanic), Joachim Brock 

(HANSA-FLEX Nürnberg, field technician), Frank Dahms 

(HANSA-FLEX Nürnberg, regional manager), Volker Schenzel 

(J. Hubert, machine operator), Patrick Goebel (HANSA-FLEX, 

fitter) and Thomas Schulz ( J. Hubert, machine operator). 

08 



hydraulIc solutIons 

tHE HArE BEAtS tHE tOrtOISE 

Flat hierarchies, rapid decision making and agility in the market: these are the HANSA-FLEX qualities dieter Hohnen appreciates. "they 

are critically important in the market. While others are still writing proposals, we are already working on the order – the hare beats the 

tortoise." It is logical, then, that Mr. Hohnen, who has a postgraduate degree in technical management, became head of the newly created 

"Industry and Mobile Services" division for HANSA-FLEX at the beginning of January. 

dieter HoHNeN, head of the new "industry and Mobile 

Services" division for HANSA-FLeX. 

the structures in place at HANSA-FLEX are an 

advantage that dieter Hohnen intends to 

consolidate and expand further in cooperation 

with his regional managers. Mr. Hohnen is an 

experienced hydraulic technician and brings a 

wealth of knowledge from his career in hydraulic 

hose and pipe connection engineering. He is already 

planning to lead industrial service "into new 

dimensions". to achieve this, the former activities 

of the FLEXXPrESS, Industrial Service, Hydraulics 

Workshop and Fluid Service divisions are being 

combined. "More and more companies are cutting 

staff in their maintenance and repair departments, 

but at the same time they need professional support 

to help them manage their tasks. this is where 

we offer our services, with an even greater store of 

expertise and capacities. We also know from experience 

that hard economic times are always good 

times for repair and maintenance operations." And 

this is where HANSA-FLEX Industry and Mobile Services 

represent services "that combine all of our skills 

and provide our customers with new options." In this 

context, dieter Hohnen points out the broad product 

programme with 24-hour delivery capability. More 

than 82,000 different components for hydraulic systems 

are available from stock on a permanent basis. 


then there are spheres of business such as cylinder 

repair, sealing technology and production of special 

pipes and fittings. "Against this background," continues 

Mr. Hohnen, "we are enabling our field staff 

to offer our customers the full spectrum of our services, 

from consulting and planning to the supply of 

hydraulic components including installing and commissioning 

the hydraulic systems. And with the development 

of the new Industry and Mobile Services 

division, we can expand these services into a truly 

comprehensive offering and take on increasingly 

complex projects." 

tHe tiMe iS riGHt For tHe 

HydrAuLiC teCHNiCiAN'S 

ProFeSSioN 

the head of the new division points out that Industrial 

Service needs trained employees for work 

because safety requirements in the industry are 

extremely stringent. "In truth there is no longer any 

getting away from the need for hydraulic technicians 

in our sector," Mr. Hohnen predicts, "because the duties 

of service technicians and fitters are becoming 

tHe NeW FLeXXPreSS veHiCLeS 2009 announce even from 

a distance that the express hydraulic service is on its way. 

more and more demanding – not least because of 

the high hourly rates that our customers have to 

consider for their production systems." In that case, 

they expect professionalism and flawless artisanal 

work, and this is provided best by experienced and 

qualified personnel. 

CLeAr diviSioN oF eFFort 

Areas of responsibility are being defined more 

clearly. With Industrial Service, the hydraulics service 

provider can offer specific capacities for lowering 

the customers' operating costs. At the same 

time, the FLEXXPrESS fleet is focussed on its core 

competency. these special vehicles serve as rolling 

workshops, from where experienced service technicians 

offer hose lines for immediate needs. In the 

hydraulic workshop, the fixed hydraulic workshop 

built on containers, the Hydraulic Service is available 

at capital construction sites at short notice, 

for minimal cost, and with extensive expertise. the 

Fluid Service offers the full range of services in the 

field of Oil Management. In another innovation, 

vehicles will also be standing at the ready with a 

mobile Fluid Service starting in April 2009. 



09

Today Industrial Hoses 

Industrial hoses from 

stock-on-hand 

All fluid lines from a single source 

"And then we need another compressor hose for air, can you deliver 

that at the same time?" Day in, day out our HANSA-FLEX offices or 

FLEXXPRESS service technicians face the same requests: their 

customers are not just asking for hydraulic hose lines, more and 

more often they also want to know when they can get 

industrial hoses. 


In the tunnelling and mining industry, for instance, 

where hoses are extremely important and enormous 

tunnel boring machines are equipped with 

hydraulic hose lines but air and water hoses are also 

needed for the underground compressors. Screed 

installers have similar needs. Their mixing machines 

have many hydraulic features but also need heavy 

duty hoses with nominal widths of up to six inches 

for pumping concrete continuously at an operating 

pressure of 85 bar. 

These customers set particularly high store by the 

phrase "everything from a single source". They want 

to cut the number of suppliers they use, and thus also 

their interfaces, and at the same time they want to 

be able to turn to suppliers they can rely on. This is 

why they come to HANSA-FLEX so often with inquiries 

about supplying industrial hoses. So what could 

make more sense than responding to the requirements 

of our customers? 

The central warehouse contains 1400 different items 

with a status of permanent availability. They cover 

an enormous range of possible applications and can 

be requisitioned for rapid delivery by any branch office 

in the world: the range of industrial hoses we 

have on hand certainly includes simple suction or 

pressure hoses for air or water that are the common 

currency of the hose-dominated tunnelling and mining 

industry; but we also offer hoses for transporting 

dairy products and vegetable fats for the food 

industry, and of course water hoses that meet German 

KTW specifications for use with drinking water. 

HANSA-FLEX also holds an inventory of drain cleaning 

hoses made from rubber or thermoplastic; these 

can be fitted with the desired connectors before 

delivery to the customer. Hoses that are used in construction 

and sewage treatment must be resistant to 

abrasive materials such as concrete, sand, gravel or 

waste water; these and others, water hoses, chemical 

hoses, even polyurethane hoses, are available from 

stock on a permanent basis. In a word: Industrial 

hoses for every conceivable purpose. 

satisfy these specifications are not even included in 

the product programme. In consultation with individual 

customers, HANSA-FLEX is also willing to 

include special parts that have not previously been 

included as items of the delivery programme, and to 

maintain a permanent stock of corresponding quantities 

for these customers. The industrial hoses, which 

undergo intensive quality control inspections when 

they are received, can be ordered through any branch 

office and will be shipped from the industrial hoses 

warehouse within 24 to 48 hours. 

Back to the tunnel: The range of industrial hoses 

offered by HANSA-FLEX is completed with specially 

designed workshop containers that are used for example 

on large building or tunnel construction sites. 

This offering is particularly useful when it is imperative 

that certain hoses are always available. And this 

includes these same, essential industrial hoses. 

Photo: Jens Frommann 

All of the industrial hoses certified according to DIN 

EN ISO 9001 that are held in the central warehouse 

meet the same high standards of quality and reliability 

our customers in hydraulic connection technology 

expect from HANSA-FLEX. This applies equally for the 

comprehensive range of accessories we hold, such as 

couplings and hose stems.The individual hose shape 

is maintained in all cases in cooperation with the 

hose manufacturers, and any products that do not 


10 HANSA-FLEX customers magazin

INduStrIAL HOSES todAy 

Photo: www.iStockphoto.com 

a sPecIalIty among sPecIalIsts 

INduStrIAL HOSES ON tHE HIGH SEAS 

Industrial hoses supply the lifeblood to heavy marine diesel engines. For example, they deliver heavy oil or coolant water to the power 

plant. A particular speciality within this highly specialised field are offshore industrial hoses, which HANSA-FLEX keeps on hand at its establishments 

in Hamburg-Stellingen and Hamburg-Wilhelmsburg for both onshore and offshore applications. 

they complement the industrial hose product 

range for general applications and are especially 

designed to withstand the additional stresses 

caused by wind, sun, seawater and vibration. Since 

both of the Hamburg sites have received specific 

certification from the marine classification society 

Germanischer Lloyd as well as other international 

classification organisations, these hose lines, with 

nominal diameters from 25 to 200, are ideal for use 

in shipbuilding. But they are just as suitable for oil 

drilling platforms, offshore wind energy farms, or 

even power stations on land. 

Wherever they are used, a considerable amount of 

technical advice is required. HANSA-FLEX supports 

its customers' design engineering departments in 

developing solutions, will provide samples and accompany 

the process until they are ready for volume 

production. 

eXPertiSe iNCLuded 

Our expertise in the field of industrial hoses, honed 

by years of experience and incidentally quite separate 

from our work with hydraulic hoses, guarantees 

that our customers will receive custom solutions. 

Skilled design and the highest quality technical advice 

are just another part of the package delivered 

by our experienced experts. they know which hose 

is most suitable for any given application and which 

safety regulations must be satisfied. 

It should be mentioned that, like hydraulic hoses, industrial 

hoses are offered with X-cOdE, because they 

are often produced in fulfil custom orders in response 

to highly specialised problems that are not immediately 

evident to other providers. this is the case for 

example when a component is inserted between 

two metals for the express purpose of blocking galvanic 

currents. It is particularly important to identify 

industrial hoses when they are intended for use on 

drilling rigs, offshore wind turbines, or marine vessels. 

If a defect should occur in these circumstances, 

a replacement part must be delivered to the platform 

by helicopter or supply boat. X-cOdE serves as a guarantee 

that the replacement part will be exactly what 

is needed. 



11

ePortAGe FIELd SALES 

not a "9-to-5" JoB 

ON tHE rOAd WItH GudruN dIttrIcH, FIELd tEcHNIcIAN 

It's a gloomy winter morning in western Saxony, thick fog blankets the landscape. Field technician Gudrun dittrich gets to the HANSA-FLEX 

branch office in Zwickau at seven. As on every weekday, this is the starting point for her regularly scheduled customer visits. 

FieLd teCHNiCiAN GudruN dittriCH on one of her visits 

for HANSA-FLeX. 


Photo: PAPP Werbeagentur 

But before she even sets out on this day, Gudrun 

dittrich helps her colleague on the early shift to 

assemble hose lines. Gudrun is a qualified BSMr 

technician, and she rolls her sleeves up. She knows 

all about that. "I've attended quite a number of 

HANSA-FLEX training courses and I've learned a great 

deal from working with my colleagues," she says. 

Gudrun started her career in the hosiery industry, 

which has a strong presence in the region. "In those 

days, I looked after packing machines, and that was 

where I came into contact with pneumatic and hydraulic 

systems for the first time." this was followed 

by several years in the machinebuilding sector and a 

brief detour into retailing. "I like selling very much, 

but I missed the hands-on technical aspect." Here at 

HANSA-FLEX, she now enjoys a mixture of both. At 

the age of 45, Gudrun dittrich decided "to do something 

new again". As luck would have it, a vacancy had 

arisen at the Zwickau office, and 

HANSA-FLEX managing director Jürgen Böttger offered 

her the opportunity to head up field service 

operations. that was five years ago. 

Five years on, customer orders for today are collected 

and brought out to the car. At 9 o'clock, Gudrun sets 

off – into the fog. Seidel Bau- und Kfz-technik GmbH 

is located in Auerbach, in the vogtland district; workshop 

manager detlef Marschner is already waiting 

for Gudrun and the fittings he ordered. the family 

company was created from a one-man business to 

rent, repair and sell JcB type construction vehicles 

(from 1.5 to 24 tons) and machinery and equipment 

for the construction industry. Accordingly, the 

company's production palette includes burst-lining 

machines for underground pipelaying and the specialised 

equipment that goes with them. "Professional 

manufacture or repair of wearing parts such as 

excavator buckets, ditch clearing buckets and special 

grabs is also undertaken. We see a gap in the market 

here," says company boss Seidel. the standard 

cylinders they need, as well as the custom 

orders such as pipe 

lines, valve 


FIELd SALES rePortAGe 

and other hydraulic accessories, are all ordered from 

HANSA-FLEX. 

everytHiNG For tHe CuStoMer 

Photo: PAPP Werbeagentur 

the fittings Gudrun dittrich brings with her today 

are among the parts that are regularly ordered from 

HANSA-FLEX, such as hose parts, gaskets and valves, 

which the customer uses for manufacturing mobile 

hydraulic systems. Of course, all twelve employees 

at Seidel followed the field technician's advice and 

have attended a training course in hydraulics offered 

by HANSA-FLEX. "We encounter new situations every 

day, we are asked to repair new machines every day," 

notes detlef Marschner, "so we often have to find 

new solutions, and we never have any problems 

with HANSA-FLEX – and with FLEXXPrESS we receive 

rapid assistance directly on-site." 

"If a customer needs help, 

of course I make myself available – 

that's essential for success!" 

"We use the X-code on all newly fitted hose lines," 

adds company owner Seidel, who is planning to 

include internally and externally stripped high pressure 

hoses in the company's offering soon. In the 

middle of the conversation, the field technician's 

mobile phone chirps, a customer needs her advice; 

she promises to look in on him later in the day. "I 

hadn't planned to stop there on my visits today, but 

if a customer needs help, of course I make myself 

available." As she is leaving Seidel Bau- und Kfztechnik, 

a familiar face appears, a few friendly words 

are exchanged, and Gudrun goes on. "that's a part of 

success as well. It is hugely important to talk to the 

customer all the time," she explains, "that is why I am 

always ready to tell people about the services offered 

by HANSA-FLEX. My most persuasive argument 

is to let them know the benefits 

of a full-range programme with 

a system partner." 

tHe GiANt eXCAvAtorS MAde by SCHoLZ bAuMASCHiNeN are fitted with the "oil Quick" automatic quick change system. 

Ms. dittrich, a qualified bSMr technician, measures the hose lines they need herself. 

We forge on through the fog, which refuses to lift 

for the entire day. the outlines of giant excavators 

rise up out of the murky countryside like primeval 

monsters. Gudrun dittrich turns into the work yard 

at Scholz Baumaschinen in treuen. She walks into 

the factory workshop with a fully assembled hose 

line under her arm just as technical consultant Mr. 

uhlmann is thumbing through the HANSA-FLEX 

catalogue and compiling a list of the parts he needs: 

pipes, flanges, valves and cowlings are required to 

convert the powerful Hitachi ZX 650 Lc. this is one of 

the 35 construction vehicles that the dealer is equipping 

with the Oil Quick fully automatic quick change 

system. And HANSA-FLEX supplies him with the assembled 

goods. "We just need to ring Ms. dittrich 

and let her know the pressure specification on any 

given machine, and that we need a suitable line in 

a given thread range; we have the hose line the following 

day. We've come to rely on that," Mr. uhlmann 

speaks warmly of their cooperation. 

GettiNG StuCk iN GoeS WitH tHe 

territory 

Gudrun dittrich arranges an appointment for the 

next day, when she and the technical consultant 

will take measurements for the ZX 650 

at Scholz. the HANSA-FLEX field technician 

says, "It's routine now, we take the 

measurements together, then the hose 

lines are made at the branch and dispatched 

as a priority." "And we know that the parts 

are designed exactly as we planned them," adds Mr. 

uhlmann. "She's always fast, and when we're under 

time pressure and things get done immediately, that 

tends to cement a relationship," he praises Gudrun's 

commitment. She replies that she has acquired most 

of her knowledge about hydraulic systems in the 

course of her daily activities, such as this. 

this knowledge also serves her well with her next 

customer, who has a problem with a sticking hydraulic 

cylinder. "I'll find out on site whether the 

problem is in the cylinder or in the machine after all," 

she says before climbing into her car and driving into 

the fog once again. She's in a hurry, because she still 

has to stop at an automotive component supplier in 

Schönheide before the end of the day. they ordered 

stainless steel threaded connections the day before, 

and they need them desperately. On a day in the 

field like today, when she drives anything up to 180 

kilo metres, there is little time to devote to the new 

customer contacts she makes regularly on her travels 

around the region. "But the customer must never feel 

as if he is being pressured! Even so, I look in on potential 

customers regularly to present our services and 

the complete HANSA-FLEX product range. Because 

field services demand total commitment." 


13

Employees Professionals for HANSA-FLEX 

Time for the 

right career start 

Professionals at HANSA-FLEX have many opportunities 


The world moves on hydraulics. These days, it is 

simply impossible to imagine our daily lives and 

work without this key technology. HANSA-FLEX 

has been at home in the world of hydraulics since 

1962. In the course of a few decades, the vision that 

Joachim Armerding and Günther Buschmann once 

pursued with entrepreneurial daring and persistence 

has become the internationally active HANSA-FLEX 

group. With a network of agencies that spans the 

globe and a roster of more than 2700 active employees, 

the enterprise is now a driving force in the constant 

evolution of fluid technology. And it has been 

recording double-digit growth for years – that too is 

an expression of the high level of customer satisfaction 

with our products and services. 

Both in OEM service and its spare parts business, 

HANSA-FLEX continues a strategy of dynamic 

growth and is always looking for new employees. 

Our doors are even open to applicants who have 

had no previous experience with the applications 

of fluid technology. "We know that there is no such 

profession as a hydraulics engineer, yet. That is why 

we have put everything in place to help motivated 

new employees become familiar with this technology," 

Britta Gottschalk, Human Resources manager 

for the company is keen to point out HANSA-FLEX's 

commitment. "Besides that, we are also constantly 

on the lookout for professionals for the commercial 

and logistical disciplines. In these cases, a technical 

background is helpful, but it is not a prerequisite for 

beginning a career with HANSA-FLEX." 

Any business that wants to grow as a service provider 

needs committed employees, to ensure that it 

achieves the desired growth in terms of personnel. 

This is why HANSA-FLEX is continually creating new 

positions for motivated individuals. The company is 

permanently looking to fill the following positions in 

all areas of operations and at all existing and planned 

agencies throughout Germany. 


HANSA_FLEX IS ALWAYS LOOKING FOR NEW EMPLOYEES 

– prior experience with fluid technology is not essential. 


PrOFESSIONALS FOr HANSA-FLEX eMPLoyeeS 

HANSA-FLEX offers enthusiastic employees a work 

environment in which further growth is actively 

pursued. Employees receive many opportunities to 

take on important tasks in an organization with flat 

hierarchies and where initiative is encouraged. In this 

way, they are able to drive their own personal and 

professional growth. Fluid technology is a growth 

technology, and as such it is constantly advancing 

into new arenas and new dimensions with innovative 

solutions. In order to satisfy this widening spectrum 

of demands, every employee receives regular 

training at the company-operated training centres 

and in cooperation with the International Hydraulics 

Academy (IHA). And one more reason why such 

priority is given to appropriately qualified employees 

at HANSA-FLEX is that personnel safety and environmental 

protection are inherent concerns in fluid 

technology. 


joiN uS NoW 

Anyone who is enthusiastic about experiencing every 

fascinating aspect of the fluid technology business 

and who wants to move something in his professional 

life will be right at home with HANSA-FLEX. 

HANSA-FLEX is also growing abroad. Wherever ideas 

and actions take on an international scale, employees 

in the German agencies will have regular opportunities 

to experience exciting work in foreign 

deployments. there is also the possibility of working 

abroad for longer periods under the auspices of the 

HANSA-FLEX group. If you want to play an active part 

in the success of our company and your own success 

is important to you, HANSA-FLEX will provide you 

with a warm welcome. 

A PLeASANt WorkiNG AtMoSPHere awaits committed employees at HANSA-FLeX. Flat hierarchies and plenty of opportunities 

to show initiative encourage employees to take on challenging responsibilities and control their own professional and 

personal growth. 

"Proper employee qualification 

is a constant theme 

at HANSA-FLEX!" 

HANSA-FLEX is looking 

for professionals 

The company is permanently looking to fill 

the following positions in all areas of operations 

and at all existing and planned agencies: 

• Marketing staff (m/f) 

• Technicians (m/f) 

• Field technicians for the mobile 

FLEXXPRESS fleet (m/f) 

• Key account managers (m/f) 

• Certified engineers (m/f) 

• MBAs (m/f) 

www.hydraulik-akademie.de 

Issue 

Schulungstermine 

April – Mai 

01. – 02.04.2009 Befähigte Person Leitungstechnik Bereits ausgebucht! Hennigsdorf/Berlin 

30.03. – 03.04.2009 Grundlagen der Fluidtechnik Teil 2 Dresden-Weixdorf 

16.04.2009 Grundlagen der Leitungstechnik Bereits ausgebucht! Bremen 

16. – 17.04.2009 Grundlagenseminar Edelstahl- und Elastomerkompensatoren Boffzen/Höxter 

20.04.2009 Grundlagen der Dichtungstechnik Eisenberg 

04. – 08.05.2009 Grundlagen der Fluidtechnik Teil 1 Dresden-Weixdorf 

14.05.2009 Grundlagen der Leitungstechnik Bremen 




08.06.2009 HYDrauLiKPresse 04|2009 Grundlagen der Dichtungstechnik Eisenberg 

Für weitere Informationen wenden Sie sich bitte an Frau Schmidt oder Frau Schubert unter Tel.: +49 351 413 97-19 | info@hydraulik-akademie.de 

15

XWorLd StAGE 37-39 

XWorld In sIBerIa 

IN tHE FOOtStEPS OF "tHE cOurIEr OF tHE tSAr" 

In a few short weeks, the XWOrLd tour will be crossing the endless expanse that is Siberia. From vladivostok, on the shores of the Pacific 

Ocean, the tour is headed to St. Petersburg on the Baltic Sea coast – and for about 5000 kilometres it will trace the journey made by the 

famous "courier of the tsar" (albeit in the opposite direction). 

the life of the Grand duke of Irkutsk is in danger: 

the tartars are threatening to invade russia's 

Siberian provinces. In order to warn the Grand 

duke, the tsar sends Michael Strogoff in a perilous 

journey from Moscow to Irkutsk - deep into enemy 

territory and surrounded by traitors and spies. By rail 

and steamboat, on horseback and wagon, and finally 

on foot, Strogoff sets out on his dangerous journey 

through Siberia. this story was told 130 years ago 

by Jules verne, in his novel "the courier of the tsar". 

Starting in July 2009, the XWOrLd tour will trace the 

events of this remarkable adventure, but in the reverse 

direction. 

this expedition of discovery will begin in late July in 

vladivostok, which was once a "forbidden city". vladivostok 

is the home port of the russian Pacific Fleet, 

and was not opened to the public until 1991. these 

days, the Navy base is open to visitors – and will also 

be the first item on the sightseeing agenda for this 

stage, before the adventurers turn their Land cruisers 

towards the vast Siberian wilderness; alone with 

themselves and pristine Nature. Only a few hotel reservations 

have been scheduled on the 14-day trip; on 

most nights, simple camps will be set up on the way. 

towards the end of the tour, XWOrLd will then reach 

Lake Baikal. It should be noted that the term "Lake" 

perhaps conjures up the wrong impression. Lake 

Baikal is the oldest, the deepest, and the largest 

body of fresh water on the planet. It holds more water 

than the entire Baltic sea, and its drainage basin 

is four times the size of Germany. On the last day of 

this stage, the tour will drive for more than 400 kilometres 

along the shore of Lake Baikal to Irkutsk, the 

destination of Jules verne's hero in "the courier of 

the tsar". then, after a brief detour to the lake itself, 

stage 38 leads the explorers into the vast emptiness 

of Siberia. the taiga fascinates with its own incomparable 

atmosphere: time seems to stand still, the 

only sign that this is not so is the eternal succession 

of night following the day. And suddenly, ultramodern 

cities spring up in the middle of the taiga, such 

as the third largest city in russia: Novosibirsk was 

only founded in 1893 (which is why the courier did 

not visit the town). XWOrLd will arrive here on the 

tenth day of the tour. "the one lived in a modern 

city, a heavily populated smudge of earth, where 

markets sprawl and shashlik smoke wafts through 

the streets; the other dwelt high in the mountains, in 

harsh, rocky ravines, under rampant bushes of tamarix 

juniper, where snow lies deep on the shadowed 

slopes for half the year." these words were written by 

renowned author chingiz Aitmatov in his novel "the 

Snow Leopard" to describe the contradictions of this 

majestic region. 

Stage 38 finally ends in Omsk, where stage 39 will 

begin on August 24. the vibrant city of Omsk stands 

at the confluence of the Irtysh and Om rivers; in the 

novel, this was where the courier barely eluded the 

tartars (before he was caught in the region of Lake 

chany). Stage 39 then passes through the more 

tranquil locales of Michael Strogoff's secret mission 

– classic russia, the Kremlin, the ancient town of 

Nizhny Novgorod, and many other stops in an absorbing 

mixture of well-known and less well-known 

marvels. And it finally concludes in St. Petersburg, 

the city built by Peter the Great, home of the worldfamous 

Hermitage and the Nevsky Prospekt – the 

city where, according to some film versions, "the 

courier of the tsar" celebrates a glittering marriage 

at the (successful) end of his journey. 


But don't rely on the rural details in the films of "the 

courier of the tsar" if you are trying to imagine the 

vastness of the Siberian hinterland. the actors who 

played Strogoff, such as curd Jürgens or raimund 

Harmstorf, were never there – they filmed in Hungary, 

Latvia or yugoslavia. And it is evident that the producers 

themselves had no real idea of the immense size 

and power of the mighty Siberian rivers, the Irtysh and 

Angara, which the XWOrLd tour will have to cross... 


StAGE 37-39 XWorLd 

"The participants head out into the vast Siberian emptiness; alone with 

themselves and pristine Nature. They set up simple camps on most nights." 




Background photo: HANSA-FLEX Event GmbH 


17

Reportage AUTHORISED MEN AT WORK 


An eye for the essentials 

preventing machine stoppages and accidents 

It's Rose Monday 2009, the day before Shrove Tuesday: a day when almost all of Germany comes to a standstill; they are celebrating 

Karneval, except in Bavaria, where they celebrate Fasching. But not everyone has stopped work. Bright and early that morning, Jürgen 

Lechermann, the manager of the Manching HANSA-FLEX agency, and Manfred Birner, the head of Manching Industrial Services, arrive 

at the Behr production factory in Neustadt an der Donau, where the Behr group of companies makes assemblies for car air conditioning 

equipment. Today the machines are quiet, and so the two men have an opportunity to carry out a visual inspection of the hydraulic line 

equipment that supplies the 21 injection moulding machines. 

The Behr group of companies is a system partner 

to the international automotive industry, and 

with 17 development sites and 28 production 

plants globally, it is one of the leading original equipment 

manufacturers for passenger and commercial 

vehicles in the world. The primary vendor is recognised 

as a pioneer in automotive air conditioning 

and engine cooling. Like all companies that operate 

hydraulic systems, Behr too is responsible for ensuring 

their safe operation, and must guarantee that they 

are always in compliance with the applicable standards 

and directives. If they are not compliant, the 

entity responsible is personally liable for any injury 

to personnel. Accordingly, the visual inspection of hydraulic 

systems is an extremely important element of 

the Ordinance on Industrial Health and Safety, which 

together with other standards and directives regulates 

the legal basis for the use of hydraulic hose lines. 

Not only does the Behr Group set an example in 

terms of environmentally friendly production processes, 

the management of the company is also well 

aware of its responsibilities in ecological matters and 

its duty to ensure the safety of those working at the 

"The visual inspection is an 

important part of the Ordinance 

on Industrial Health and Safety!" 

plant. Everything possible is done here to prolong 

the service live of the machinery, and thus also to increase 

the level of safety for the personnel. Naturally, 

this also means that checking the hydraulic equipment 

is given high priority. As a safety-conscious 

plant operator, Behr ensures that this visual inspection 

is carried out by an appropriately trained and 

duly authorised person. This is prescribed for example 

in occupational health and safety rule BGR 237. 

The rule provides operators of hydraulic equipment 

with a practically oriented guide to working with 

hose lines correctly and also specific help in assessing 

risk. It also gives a detailed description of the scope 

and criteria to be applied when testing. 

HANSA-FLEX has taken on the task of visually inspecting 

the hydraulic systems at the Behr production 

factory in Neustadt/Donau, where complete 

air conditioning assemblies are manufactured. The 

hydraulics service provider employs a pool of authorised 

and qualified personnel. It offers its customers 

this service in order to maintain machine availability 

and at the same time to provide system operators 

18 HANSA-FLEX Customers magazin

AutHOrISEd MEN At WOrK rePortAGe 

with professional support as they fulfil their obligations 

to protect their workers and the environment. 

At the Behr factory in Neustadt/donau, individual 

components are assembled to produce engine cooling 

components. the finished products are known as 

highly integrated systems. these front-end modules 

have been optimised for the installation space in the 

vehicle, and they include all the components necessary 

for cooling the engine. the plastic parts that are 

fitted in the module are produced in injection moulding 

machines. 

WHeN LoNG-diStANCe ruNNerS 

CAtCH tHeir breAtH 

this morning, the two authorised representatives 

from HANSA-FLEX begin working straight away to 

take full advantage of their narrow window of opportunity. 

Just as millions of "fools" were scrambling 

for the traditional "Kamelle" sweets thrown from the 

floats, Jürgen Lechermann and Manfred Birner were 

scrambling under the injection moulding machines 

and inspecting the hydraulic lines. the 21 modern 

moulding machines, made by manufacturers 

KraussMaffai and Engel, are the heart of production 

at Behr's Neustadt factory. It is here that the vehicle 

air conditioning components are manufactured, cast 

and assembled, and then delivered directly to the 

assembly lines of the vehicle manufacturers "just-insequence", 

i.e. at exactly the time they are needed for 

fitting in the vehicle. the time between receipt of the 

order and delivery to the customer for immediate fitting 

on the assembly line is just a few hours. there is 

no time for unscheduled machinery stoppages. this 

inspection also serves to maintain high system availability 

and minimise repair costs. this is important, 

because of course the operational safety of hydraulic 

systems also has a financial benefit. "during the 

visual inspection, we work from the checklists developed 

and provided by HANSA-FLEX. they are well 

organised and enable us to record and document our 

viSuAL iNSPeCtioN of the outside of the machine by jürgen 

Lechermann, head of the HANSA-FLeX Manching agency. 

Photo: HANSA-FLEX Manching 

observations precisely for each machine," says Jürgen 

Lechermann. the visual inspection checklists have 

been prepared by HANSA-FLEX in accordance with 

the specifications of regulations and legal provisions 

so that nothing is left to chance and the systems are 

inspected according to strictly defined points. 

Accompanied by Klaus Achhammer, Behr's master 

craftsman in the plastics workshop, the two authorised 

HANSA-FLEX representatives set about their job. 

"First we inspect the hydraulic line equipment on all 

21 machines," says Jürgen Lechermann. "this visual 

inspection is designed to catch early signs of wear as 

well as any evident damage. We then document the 

results for each individual machine. If we detect any 

defects, we record our recommendations for correcting 

them." And these recommendations are a fixed 

part of the final report. And Jürgen Lechermann and 

Manfred Birner pay very close attention. they consider 

the operating sequence of the machines, the 

ambient conditions, and how all these factors affect 

the adjoining equipment. 

Both inspectors have been qualified and authorised 

by HANSA-FLEX, and they are able to detect possible 

dangers and suggest suitable measures for preventing 

damage to the hydraulic hose lines. the injection 

moulding machines are "long-distance runners". 

they are subjected to high stresses and a great deal 

is required of them. temperature changes in the 

workplace affect the polymer curing process in the 

hose lines, and the constant work cycles with their 

relentless pulses to open and close the casting mould 

exert a load on the entire hydraulic line system. 

HANSA-FLEX is well acquainted with the production 

conditions and the hydraulic systems at Behr, after 

all, the Manching agency has been working with the 

automotive supplier for twelve years now. Jürgen 

Lechermann and Manfred Birner know exactly what 

they have to look out for. 

A tHorouGH oNCe-over iN tHe 

NAMe oF SAFety 

"First we note down all the hose lines that are exposed 

and visible," says Manfred Birner, "but then 

we must also assess all the hoses inside each machine." 

this two-stage approach to the inspection 

reflects the high potential for a threat to employee 

safety. Jürgen Lechermann also carried out a hazard 

analysis, in which he inspected all visible hose lines. 

the second stage was then conducted inside the machines; 

this phase is intended to prevent unscheduled 

machine downtimes. "that part also involved a great 

deal of disassembly and reassembly, because many 

machine parts needed to be removed before the hose 

lines could be inspected and replaced if necessary." 

In the machine room, for example, the lines for the 

mould closing mechanism are checked, the injection 

moulding device is inspected on the plastic side, and 

all units on the pump side are noted. On Shrove tuesday, 

with Fasching and Karneval in full swing, Jürgen 

Lechermann and Manfred Birner record each anomalous 

observation that might indicate the beginnings 

of line damage. they proceed step by step, using the 

"Hydraulic line equipment" checklist as a reference. 

the entire inspection procedure is carried out in a 

well-organised sequence that can be reproduced at 

any time. After two days of thorough inspection, they 

conclude: "Some hose lines should be rerouted and a 

few hose lines should be replaced as a precautionary 

measure." 

eXCeLLeNt reSuLt ANd A FeW 

SMALL tiPS 

With particular concern for employee safety, "we 

also advised them to fit interlocks on the machines," 

adds Manfred Birner, "because they prevent the hose 

from thrashing uncontrollably if it suddenly breaks 

away." the two specialists also looked more closely at 

the spots where the hose lines were rubbing against 

the machines. In these cases, they recommended the 

use of protective sleeves to prevent the hose mantles 

from being damaged. All of their recommendations 

were recorded in the written inspection report, which 

Jürgen Lechermann and Manfred Birner handed over 

to the system operator at the end of their visual inspection. 

this report not only serves to document 

the inspection, it is also represents evidence of the 

operator's timely action. "this report gives us some 

guidance on what we can do to avoid unintended 

machine downtimes, to prolong the service life of 

the hose lines, and so to increase the safety level 

for our employees," says Klaus Achhammer from the 

Neustadt Behr plant. By Ash Wednesday, it was all 

over – Behr's 21 injection moulding machines were 

ready to begin working safely and reliably again. And 

now the two authorised specialists from HANSA-FLEX 

have time to celebrate as well. 

Photo: HANSA-FLEX Manching 

A CAreFuL eXAMiNAtioN of hose lines and fittings by Manfred 

birner, head of Manching industrial Service. 


19

At Work HydrAuLIc PIPELINES 

hydraulIc lIne equIPment 

dESIGNING PIPELINES cOrrEctLy LOWErS OPErAtING cOStS 

Hydraulic energy is best transferred through pipelines with fixed connections. If more than one pipeline is used, and the same hydraulic 

fluids are being transported, and the same measurement pressures and temperature conditions exist, this is referred to as a pipeline 

system. When designed and installed in accordance with specifications, pipeline systems are a safe, reliable tool consisting of hydraulic line 

equipment. 

the advantage pipelines have over hose lines is 

that the volume of hydraulic fluid they contain 

is more consistent, which results in a low loss 

transfer of power. When they are installed in pressure 

lines, return flow lines and intake lines, they can 

withstand high internal pressures, resist dynamic 

pressure profiles, and when they are configured and 

attached correctly, absorb high external loads. Pipelines 

have a natural elasticity, which can be used to 

advantage for stress-free installation if assembled 

correctly. they can be made from standard commercial 

materials and used for a wide range of operating 

temperatures. their walls are very rigid, and this 

prevents pressure spikes from being damped. these 

pressure spikes are propagated as pressure waves in 

the hydraulic fluid at what is known as the oil speed 

of sound, and they generate dynamic forces, particularly 

in curves. considerable advantages can be 

gained from the many connection designs reflecting 

the state of the art, and the economical working of 

the pipe from its raw delivered condition to one in 

which it is ready for installation on construction sites 

and in workshops. 

Photo: Helmut Wetteborn 

PrACtiCAL iMPLeMeNtAtioN 

the standard principle of safety in hydraulics, as 

expressed in laws, government orders, guidelines, 

regulations and standards, applies without limitation 

to pipelines as well. Maximum safety in all 

phases of order processing and operation is therefore 

predicated on the requirement to design, manufacture 

assemble, commission in accordance with specifications, 

and to carry out regular inspections during 

operation. As a part of the line equipment, of course 

the pipelines must be considered in hazard analyses 

of the overall hydraulic system described above. Naturally, 

the scope and content of order processing are 

dependent on the scope of scope of work. In general, 

however, the following must be taken into account: 

• Design of cross section according to specification 

with minimal pressure losses 

• Measurement of wall thickness according to regulations 

for straight and bent pipelines 

• Consideration of temperature conditions by selection 

of materials and pressure reduction 

• Consideration of the differences between installation 

and operating temperatures by applying 

proven installation principles and compensation 

• Use of common routing for hose and pipelines in a 

mixed construction environment in order to damp 

pressure and compensate for length 

• Use of the standardised range of fitting designs as 

technically feasible loose bearings 

• Freedom from leaks at connection points 

• Corrosion protection as stipulated 

• Measures to prevent electrostatic charging 

• Compatibility with pipeline connections in terms of 

pressure and dimensions 

the following illustrations show a conventional design 

for pipelines: 

Fig. 2: valve connections 

Fig. 3: Cylinder connections 

Photo: Jens Frommann Photo: Helmut Wetteborn Photo: Helmut Wetteborn 

Fig. 1: Pipeline system 

Fig. 4: Pipeline guides in mixed construction 


HydrAuLIc PIPELINES At Work 

Pressure waves, delivery flow pulses and oscillations 

require special treatment when the pipelines are being 

designed, configured and installed. the following 

state of the art is recommended for future-proof solutions: 

• Use pressure control values in compliance with 

specifications 

• Increase the natural elasticity of pipelines 

• Fit hose lines where pressure fluctuations are minor 

• Fit hose lines for damping pressure 

• Fit accumulators in environments with wide pressure 

fluctuations 

the basis for orders according to the assignment of 

tasks are the comprehensive, standardised technical 

conditions of delivery for steel and stainless 

steel pipes. the orderer's regulations, permits, plant 

standards and installation conditions on site also affect 

the scope of technical services. design methods 

are based on the experience of the design engineers 

and fitters, the manufacturer's instructions and the 

proposal, as well as the following standards: 

• DIN 2413 

• DIN EN 13480-3 

• DIN EN 13480-4 

• DIN 2353 

• DIN 2445, supplementary sheet 1 

• DIN ISO 13763 

the effects that fixing, compensation for elongation 

and connecting a pipeline have on the construction 

and assembly of the pipeline must not be underestimated; 

these effects must be considered both for 

the single component and for the overall system. the 

necessary bending processes, transport conditions 

and construction or workshop manufacture as well 

as flushing and commissioning services also play into 

the costs. 

the following illustrations show examples of properly 

designed fittings: 

Fig. 6: Steel pipe clamp HSr 

Like hose lines, non-conforming pipelines must also 

be identified by the manufacturer. Other, additional 

machine- and device-related identifications ensure a 

clear view, support the assembly processes and the 

prescribed inspections. 

In order to preserve the natural elasticity of the pipelines 

and ensure the necessary length compensation, 

the L-bend, Z-bend and u-bend routing principles 

are to be used. this is the only way to ensure that the 

reaction forces on the machinery and device connections 

are kept within manageable magnitudes and 

do not destroy the delicate pipeline connections. In 

particular, pipeline guides between two opposite 

connections produce reaction forces that can damage 

the connections or at least impair their seal in 

the long term. the underlying cause is the change in 

the pipe's linear length brought about by the temperature 

difference. the greater the difference and 

the longer the pipe, the greater the reaction force. 

the reaction forces in this case are also greater than 

the holding forces of standard commercial pipeline 

L S [ mm ] 

800 

700 

600 

500 

400 

300 

l 

for ferritic and 

austenitic pipe steels 


l 

clamps. therefore, when selecting and attaching 

pipeline clamps, it should be understood that they 

generally only serve as a guide for the pipe. the connection 

itself necessarily becomes the fixing point 

and must sustain all the forces that act on it. detailed 

calculations are recommended for the design engineering 

proof of natural elasticity and the reaction 

forces. this can be accomplished more quickly and 

with sufficient accuracy with the aid of the graphic 

below (see Figure 7). 

CoNCLuSioN 

Pipelines that have been designed, configured and 

installed in accordance with specifications are an 

excellent technical means for transferring hydraulic 

energy. they will function safely if they are routed 

in compliance with proven principles. using the 

pipeline's natural elasticity helps to preserve its seal 

for the long term, prevents the risk of rupture even 

under fluctuating loads, and it is generally recommended 

for use besides having a longer service life 

than hose lines. detailed illustrations and practical 

tips for designing energy-efficient pipelines in 

compliance with regulations and configuring them 

in accordance with specifications as well as essential 

safety instructions are contained in the practical 

manual "Hydraulic line equipment" written by dipl.- 

Ing. Helmut Wetteborn. 

L S L S L S 

l 

D = 100 mm 

D 

D = 65 mm 

D = 50 mm 

D = 42 mm 

D = 38 mm 

D = 30 mm 

D = 25 mm 

D = 20 mm 

D = 15 mm 

200 

100 


D 

L s 

l 

0 

1,5 2 2,5 3 4 5 6 7 8 10 

external pipe diameter 

length of pipe leg, Z-bend, U-bend 

pipe reference length 

l [ m ] 

Abb: Helmut Wetteborn 

Background photo: Julia Ahlers 

Fig. 5: Standard pipe clamp conforming to diN 3015 

Fig. 7: Natural elasticity resulting from routing principles 


21

HANSA-FLEX Dienstleistungen 

Lower costs, raise performance – HANSA-FLEX Solutions can do that 


Tight deadlines, mounting competition and relentless budget concerns are driving the OEMs to optimise and minimise the costs of purchasing 

spare parts as well as production processes and workflows. HANSA-FLEX Solutions address these needs directly with customised 

concepts. 

Rapid supply of spare parts 

The solutions start with spare parts purchasing. A 

tightly knit network of agencies guarantees that the 

parts needed are available quickly. This high-quality 

service is based on a permanent inventory of more 

than 82,000 different components, which can be delivered 

within 24 hours. It is assisted by the serviceoriented 

structure of the agencies themselves, with 

experienced, motivated employees who are ready to 

help with their technical knowledge and commitment 

to service in every situation. 

Adding more value for OEMs 

The Bremen-based hydraulics company specialises in 

customised concepts for improving the valued added 

chain of OEMs. If OEMs want to improve their logistics, 

increase mobility or raise productivity, they can 

do all this with HANSA-FLEX Solutions. Service modules 

such as "kanban and consignment warehouses", 

"kitting" and "plant in plant" have proven particularly 

effective. These OEM services are customised and 

synchronised perfectly with the respective production 

processes. 

Kanban and consignment 

warehouses 

Kanban and consignment warehouses are one of the 

logistical solutions that have already been created 

in close cooperation with the OEMs. HANSA-FLEX 

kanban warehouses offer the customer a structured 

and regularly maintained stockpile of hydraulic components 

on site for production lines. The necessary 

products are always ready to hand for the fitters; 

time-consuming planning and ordering processes 

are superfluous. Kanban warehouses can also be 

managed as consignment warehouses. In this case, 

the components initially remain the property of 

HANSA-FLEX, and do not become a cost factor until 

they are removed from the warehouse. In this way, 

the customer only pays for what is actually needed. 

Kitting 

Fluid technology is complex. Fitters must not only 

install hose lines, but also many associated components 

including pumps, insulating material or 

electronics. Ordering and facilitating delivery of the 

required parts from a number of different manufacturers 

is a time-consuming, cost-intensive pastime. 

This is where HANSA-FLEX offers the kitting 

module. In kitting, pre-assembled sets are supplied, 

ready for installation. Besides the components from 

HANSA-FLEX, they may also include all the parts 

from third party suppliers, ready for the respective 

installation step. HANSA-FLEX develops the complete 

kits jointly with the customer, including the correct 

arrangement of parts for removal and optimum 

22 


SOLutIONS HANSA-FLeX 

packaging. this principle ensures maximum reliability, 

because there can be no missing parts and they 

cannot be mixed up. At the same time, interfaces are 

reduced, initial costs are minimised and productivity 

is increased permanently. 

PLANt-iN-PLANt 

the "plant-in-plant" concept enables the 

HANSA-FLEX programme of services an and products 

to be fully integrated with a customer's production 

workflows - including shiftworking if applicable. For 

this, HANSA-FLEX maintains a production facility at 

the customer's own plant, with a defined parts warehouse 

and all necessary machinery. the customer no 

longer needs to maintain its own fluid technology inventory. 

Warehouse costs are saved, the capital tied 

up in inventory is released, and there are no internal 

logistics costs. Incorrect orders are a thing of the past, 

overstocks and obsolete hose items no longer need 

to be charged off. response times for product delivery, 

spare parts delivery or sample construction are 

extremely short. this allows the customer immense 

flexibility, because a contact for all technical and 

commercial questions is always on site; fast, direct 

communication avoids information disconnects. 

unexpectedly high demand caused by increased production 

can be covered easily at any time. 

HydrAuLiC WorkSHoPS 

tunnels and large construction sites are often located 

in areas with a weak infrastructure. valuable time is 

lost waiting for a replacement hose line to arrive. the 

solution: HANSA-FLEX hydraulic workshops, which 

render construction sites independent of the long 

delivery times for spare parts. the workshops are 

fully equipped containers for making high-pressure, 

hose and pipe connection equipment. the hydraulic 

workshops are well-organised and configured identically. 

Anyone who has worked in one will have no difficulty 

in finding everything the next time. And if the 

construction site moves on, the container is already 

there. Hydraulic workshops can be integrated in the 

manufacturing processes of industrial operations just 

as efficiently. the equipment they contain is adapted 

to the needs of the customer in each case. 

FLuid ServiCe 

Practical experience has shown: 75 percent of all 

pressure media in hydraulic systems is heavily contaminated. 

Even unused oil is often contaminated 

before it is delivered. dirty hydraulic oil has been the 

cause of many a machine failure, wear and unscheduled 

downtimes. 

the fluid service offered by HANSA-FLEX uses active 

oil management to address the source of the 

problem directly. this includes analysing fluids and 

evaluating the working environment of a hydraulic 

system, and recommending corrective measures. 

thus for example, plant for hire and auxiliary filtering 

agents are available at all times to clean fluids without 

interfering with operations, thereby creating the 

conditions for uninterrupted work. capacities are 

also maintained so that even structural changes can 

be made at short notice. When ventilating tanks, for 

example. Effective immediately, the Fluid Service is 

now ready available on the market with its own fleet 

of vehicles. Each vehicle carries all the analysis instruments 

necessary for mobile use and a selected range 

of auxiliary filtering agents. 

SPAre PArtS LoGiStiCS 

oPtiMiSed WitH X-Code 

Since its introduction in 2004, the HANSA-FLEX 

X-cOdE has revolutionised spare parts procurement. 

the six-position alphanumeric code for unique labelling 

of components enables any hydraulic hose connection 

to be identified with complete confidence. 

If the situation requires, the code in question can 

simply be quoted and the database will ensure that a 

replacement part of identical construction will be delivered. 

Misunderstandings, delays, and complaints 

are avoided. Specifications can be made in addition 

to the X-cOdE standard: X-cOdEplus offers additional 

modules that help to improve availability of hydraulic 

systems and lower costs. X-cOdE OEM supports 

original equipment manufacturers in optimising 

their manufacturing processes, and offers new opportunities 

for improving service quality. 

MobiLe ServiCeS 

the newly formed HANSA-FLEX Mobile Services business 

unit also supports customers with customised 

installation services. Service technicians from the 

industrial service sector are available to carry out 

preventative maintenance. It is recommended that 

their services be used when maintenance, assembly 

or conversions of hydraulic systems can be carried out 

during scheduled downtimes of the system. If a hose 

line needs to be replaced immediately, the mobile 

FLEXXPrESS rapid hydraulic service is ready to spring 

into action. 




CoNSiGNMeNt WAreHouSeS make work easier for 

cooperation partners – the hydraulic components are 

replenished constantly, and they are only billed for the parts 

they actually use. 

kittiNG is the programme in which complete assembly sets 

are put together for specifically defined applications. they 

contain all the single components needed – including those 

from third party suppliers. 

PLANt-iN-PLANt integrates all HANSA-FLeX services and 

products in the production workflows by setting up a production 

facility at the customer's own factory. 


23

WORK & LIFE The Eye 


A quick look at looking 

OUR EYES ARE FASCINATING SENSORY ORGANS, AND IT IS IMPORTANT TO PROTECT THEM 

"Light conveys the visible to the eye; the eye conveys the visible to the rest of the beholder. The ear is dumb, the mouth is deaf, only the 

eye can hear and speak. It reflects the outside world inwards, and the inner life of a person outwards. The totality of the internal and the 

external is accomplished through the eye." These words were written by Johann Wolfgang von Goethe in "Farbenlehre", his treatise on 

colour in 1810. 

And with that he said practically everything 

there is to say about the human eye. The eye 

is without doubt our most important sensory 

organ - more than ever in today's world, dominated 

as it is by visual stimuli. No other sensory organ provides 

us with anything like as much information; humans 

receive approximately 70 percent of all important 

information through their eyes. But the eye is 

good for so much more than that: we flirt with pretty 

eyes or lose ourselves in their depths, we impress the 

people we are talking to with an honest, candid gaze; 

we seek eye contact and through our eyes we express 

fear, horror, anger, arrogance; they shine to show we 

are happy. In a word, we "talk with our eyes", we 

communicate with them. 

The eye is one of the most fascinating organs in the 

human body. It is connected directly to the brain by 

more then 60 million nerve fibres. Our eyes function 

with incredible precision, almost ceaselessly: 

constantly in motion, they focus instantaneously on 

exactly what we want to see. Unlike a camera lens, 

the eye can move and train itself on new stimuli in 

....well, the blink of an eye. Each glance stimulates 

many different areas of the brain, not only those 

tasked with controlling the eyes, but also the areas 

that analyse and process image information. To enable 

this to happen, each eye is controlled by both 

halves of the brain, and the nerves of the pupillary 

pathways have to cross over each other. The field of 

vision of all eyes is divided in half vertically. For example, 

the outer region of the left eye is also processed 

by the left hemisphere of the brain, but the 

region closer to the nose is controlled by the right 

hemisphere. 

How does seeing work? A light source such as the sun 

radiates white light, which contains all wavelengths 

of the colour spectrum, at an object, for example the 


tHE EyE Work & LiFe 

leaves on a tree. the leaves absorb all the light wavelengths 

except those we perceive as green. the light 

that is then reflected from the leaves passes through 

the lens in our eyes and strikes the retina, where it 

excites the corresponding photoreceptors. this information 

about the composition of the light ray is 

converted into neural stimuli. this is used to construct 

the image of the tree in our perception in the 

visual centre of our brain. the information is carried 

to the brain by the optic nerve, which is three to four 

millimetres thick, 25 millimetres long, and consists 

of a million fibres. However, the actual image is only 

formed in the person's brain, or more precisely in the 

visual centre at the back of the head. Incidentally, we 

are able to recall images that we have seen once from 

our long-term memory, so that they are available in 

our short-term memory, so to speak. For example, 

when we remember a picture or situation. 

it NeedN't eNd iN teArS 

When one learns about the extraordinarily complex 

structure and important function of the eye, the 

phrase "the apple of my eye" takes on a whole new 

immediacy. After all, how is the eye protected? the 

eyelashes serve as a natural protection, as does the 

lightning quick response of the eyelid, which closes 

when sudden dangers occur. 


But that is just a minimum protection provided by 

Nature, the person himself is responsible for everything 

else. And everyone is well aware of how important 

it is to protect one's eyes. Whether at work 

or in recreation. unfortunately, eye injuries caused by 

acids, alkalis or adhesives are the most common of 

workplace accidents. Mechanics and service technicians 

who work on hydraulic systems, for example, 

should therefore take care to wear protective goggles 

at all times. they help to prevent the eyes from being 

damaged by spraying oil or liquids. 

Protective goggles are also a must for assembly work 

on mobile hydraulic systems; especially when working 

under a vehicle. Because it is all too easy for a tiny 

particle of dirt or rust to fall off the bottom of the vehicle 

and lodge itself in an open eye. Particular care 

is also recommended when welding: looking at the 

welding arc for just a split second without goggles 

can cause a flash burn. this is an extremely painful 

condition, because welding arcs injure the eye in the 

same way as sunburn injures the skin. 

People who sit in front of a computer should tear 

their eyes away from the screen more often, because 

even seeing can be tiring. Monitor work is hard labour 

for the eyes. Whereas the eye normally wanders 

freely from one object to another, in front of a 

computer monitor is it forced to adjust constantly to 

changes in brightness and distance, and at the same 

time it is being underused, as it is fixed fairly rigidly 

at the same angle and on the same objects. 

It is worth taking more care of your eyes and focussing 

on their health. After all, they are our "windows 

on the world". And preventative eye examinations 

are now mandated by law in the German Screen 

Work Ordinance. But even without legislation, everyone 

should exercise foresight, and have their eyes 

checked regularly, especially after the age of 40. 

ProteCtiNG our eyeS should have highest priority, not 

only at work but in our leisure time as well. Chemical burns 

from acids or alkalis, and injuries due to dirt particles are 

the most common causes of accidental damage to the eyes 

yet they can be avoided very easily by wearing protective 

goggles. 



25

SoLutioNS PrEFOrMEd HOSES 

In good shaPe for tIght sPots 

PrEFOrMEd HOSES ANd BENt PIPES FOr SPEcIAL cASES 

Willingness to take on challenges has always been an important feature of way the HANSA-FLEX pipe bending centre in Schönebeck does 

business. Now that the Preformed Hoses business unit has been integrated at the site, boss ralph rehberger and his staff will have two 

service areas demanding their attention: with immediate effect, they are responsible for production of both preformed hoses and bent 

pipes. At the same time, Schönebeck is expanding its production of bent pipes and its supply of complete assemblies in order to win new 

customer groups. 

Preformed hoses are needed in places where 

space is limited. they transport charge air, exhaust 

air and coolant water for engines, for 

example in construction machinery or ships' power 

plants. As these machines are constantly being made 

smaller, the space left for installation is often limited 

and complicated. then it becomes necessary to use 

geometries and bending radii that are difficult to 

create with pipe lines. But highly flexible preformed 

hoses can match almost any bending radius, and 

can compensate for tolerances better. they also 

help to damp oscillations and decouple vibrations, 

used together with pipelines they compensate for 

expansion. 

beNt PiPeLiNeS and preformed hoses are essential for 

installations when space is very limited. 

Photo: Stahl Konecranes GmbH 


OEM customers benefit especially from preformed 

hoses. cleverly designed preformed hoses can significantly 

reduce manufacturing costs. Nowadays, more 

and more vehicle manufacturers are using preformed 

hoses because they can be adapted to assembly conditions 

easily and fitted precisely in the limited space 

of the housings. these flexible hoses can also be installed 

and removed from engines without difficulty. 

And they can be conformed to the most complex 

geometries. Whereas in many cases pipes have to be 

shaped from a large number of segments and then 

welded, preformed hoses can be bent easily and 

compensate for minor differences between the line 

ends they connect. Since they also absorb thermal 

expansion more simply, they present a minimal risk 

of leaks. 

Preformed hoses even perform very well in long sizes, 

because they absorb the vibrations in the structure. 

All these arguments recently prompted a manufacturer 

of straddle carriers - those large, spidery vehicles 

that are used to transport containers in ports - to 

replace the coolant water pipelines with preformed 

hoses in its entire inventory worldwide. this improved 

their availability considerably. 

Even before now, HANSA-FLEX carried a stock of preformed 

hoses in the 90° range and many nominal 

diameters for standard applications. this expertise 

in preformed hoses will now be merged with the 

pipe bending centre in Schönebeck. With the Preformed 

Hoses business unit, customers will now 

have the choice of both. they will be able to consider 

either preformed hoses or bent pipes in their 

circuit designs for coolant water, air and exhaust. 

thus, HANSA-FLEX's customers may be sure that 

they have the best technical solution in all cases. the 

parts required will be drafted at a cAd workstation 

in the pipe bending centre, and will be created with 

all specifications, including the shape of the mandrel 

for producing the preformed hose or the bending 

program with all parameters. the line experts in 

Schönebeck will also draw complete pipeline sets 

with die rings and coupling nuts, and will submit 

them to the customer together with a bending plan 

in one document for the customer's workflows. the 

detailed pictures not only help the customer to visualise 

the part, they also make it easier to put together 

whole kits. For spare parts business, both pipes and 

preformed hoses will be scanned in Schönebeck, 

their coordinates will be entered and single items of 

identical construction will be produced. If tool costs 

are no object, even the owner of a vintage Maserati 

can get the part he needs to get his ride back on the 

road again. 

FroM bLANk to PreForMed HoSe 

Especially in new constructions, preformed hoses are 

designed specifically to the individual requirements 

of the manufacturers in terms of length and bend. 

First, a "shaped mandrel" is constructed on the basis 

of these requirements. this is a metal blank, usually 

made from steel or stainless steel, in the same shape 

as the subsequent hose connection. the outer shape 

of the mandrel therefore reflects the inner shape of 

the hose. Strips of the hose material are then wound 

round the mandrel and sintered, in other words they 

undergo a shaping manufacturing process. In this 

process, in-place vulcanised metal parts or precured 

rubber components can be used to create an enormous 

variety of connecting and fixing options. 

PreForMed HoSeS are made from metal on a "forming 

mandrel" which determines the shape they will have later. 



PrEFOrMEd HOSES SoLutioNS 

beNt PiPeS iN SerieS ANd AS kitS 

HANSA-FLEX is always ready to take on any challenge 

the customer can think up, and now supports 

manufacturers with bent pipes up to six metres long 

for hydraulic line equipment in many variations. For 

example in wind energy, the market of the future, 

bent pipes are available for everything from cooling 

lubricant lines to the hydraulic line equipment for the 

rotor blade adjusting cylinders. Standardised quality 

practices ensure that specified geometries are copied 

exactly, and that the insides of the pipes are cleaned 

to meet the manufacturer's standard. 

CoMbiNed SoLutioNS MuLtiPLy 

kittiNG oPtioNS 

New options are being revealed in the Kitting business 

unit. Now that both business units are under 

one roof in the Schönebeck pipe bending centre, 

HANSA-FLEX is able to assist its customers optimally 

with combinations of this kind. For example, a 

manufacturer of heavy duty compressors may receive 

ready-to-fit high pressure line assemblies for the 

hydraulic system as well as bent pipes and adapted 

preformed hoses for air and liquid coolant management. 

With the convenience of a single source – the 

assemblies are put together in Schönebeck and 

shipped out to the customer's assembly position at 

the agreed time. 

the preformed hoses and bent pipes produced in the 

pipe bending centre in Schönebeck can be obtained 

from all HANSA-FLEX agencies. With service, manufacturers 

can improve their production logistics, for 

instance, and cut costs at the same time. For example, 

very recently a major crane manufacturer received 

a large order of the assemblies it needed from 

the HANSA-FLEX agency in its area; the assemblies 

were delivered on racks that were configured to reflect 

the assembly workflows in production exactly. 

Each component simply needed to be taken, without 

an irritating search. the agency hired a hall for this 

service, and takes responsibility for ensuring smooth 

delivery processes. 


Photo: Stahl Konecranes GmbH 

27

NeWS AIr cONdItIONING tEcHNOLOGy 

keeP cool When thIngs heat uP 

tHE FASt HOSE FOr A HEALtHy AtMOSPHErE 

the sun is beating down on the container crane. Even the light breeze from the sea offers little respite. up in the glass-encased cab, and 

high above the ship, the operator has no time to worry about anything but his job. His shift lasts eight hours, and in that time he will shift 

as many as 200 containers – without breaking a sweat. Because his "office" is equipped with an air conditioning system, which ensures his 

cab remains at a comfortable temperature. 

these days, air conditioning systems are used in 

many places to provide temperatures that correspond 

exactly to the needs of the situation. 

Whether it be in work positions, such as trucks, excavators, 

logging machines, goods handling equipment, 

or in the passenger cabins of cars or buses. 

Passengers now expect comfortable air conditions 

even in underground railways, trams and trains. 

Many manufacturers and operators of the vehicles 

described have long relied on line equipment from 

HANSA-FLEX when it comes to hydraulic systems. 

And more and more often these customers are also 

asking for help with air conditioning; after all, air 

conditioning systems are also just means to control 

fluids built with the best hose line equipment. As a 

result, HANSA-FLEX has decided to include cold air 

equipment in its product range. Not only in terms 

of spare parts, for also the original equipment. this 

decision was based on HANSA-FLEX's many years of 

experience with this technology, occasionally gained 

in cooperation with customers. this experience will 

now be extended to the entire HANSA-FLEX Group. 

And this entails considerable investment, not only in 

the expansion of our product range, but also in the 

skills of our employees. Skills will be learned in a series 

of targeted training courses. 

HANSA-FLEX has the capability to manufacture, install 

and repair all cold air hose lines, for fixed and 

mobile applications. this service is available to OEM 

with the most stringent specifications regarding 

punctual delivery of volume products as well as customers 

who simply want to find a spare part quickly. 

Service providers that support cold air equipment 

to their customers as a service are also welcome. 

For these companies, the HANSA-FLEX agencies can 

provide a local staging post as a supply base for their 

air conditioning hose and fitting needs. If they wish, 

air conditioning service providers can contract with 

us to ensure that we maintain a permanent stock of 

specific parts. 

rePLACeMeNt PArtS iN oriGiNAL QuALity enable help 

to arrive quickly when the delivery times for original parts 

are too long. All agencies keep a wide range in permanent 

stock for just such an eventuality. identical matches can be 

made even for special fittings and manifolds. 



uNCoMProMiSiNG iN diFFuSioN 

ANd eFFuSioN vALueS 

We use proven multipurpose coolant hoses with the 

corresponding aluminium or steel connectors and fittings. 

these are barrier or rubber hoses with nominal 

diameters 4-24, all of which surpass the standards 

that currently apply for diffusion and effusion values 

in the air conditioning industry. the E-Z clip system 

with soldering kit will be used for fast repairs; with 

this method, repairs can be carried out quickly, without 

moulding or screws. 

With the "fast hose", HANSA-FLEX can repair air 

conditioning systems quickly, cheaply and safely, 

thus minimising unscheduled downtimes. this is 

especially welcome when the original parts are associated 

with long lead times, which in turn result in 

high costs. We can help immediately with "replacement 

parts of original quality" and a highly diversified 

product range, because each agency will have a 

well stocked range of hoses on hand. Moreover, even 

special fittings or pipe manifolds will no longer have 

to be returned for repair. A part can be built to the 

identical specifications, using the defective part as 

a pattern. HANSA-FLEX is also able to manufacture 

hoses, threaded connections and filling tubes quickly 

to order. 

HANSA-FLEX's strengths as a system partner only 

become more apparent with original equipment. In 

this case, the extrusion process is also used for volume 

production. From prototyping to the start of 

volume production, everything can be processed in 

short order and to the most demanding standards. 

One service that will be helpful to all OEMs that offer 

cold air temperate workstations and want to extend 

this extra to machine equipment at an affordable 

cost. Since HANSA-FLEX can also deliver entire assemblies 

for cold air conditioning equipment – and 

of course also for hydraulic line equipment – the idea 

of the "one-stop shop" is attractive. this will enable 

to customer to reduce its interfaces and tighten up 


AIr cONdItIONING tEcHNOLOGy NeWS 

"HANSA-FLEX is able to manufacture, install and repair 

all cold air hose lines, for both fixed and mobile applications!" 

Purchasing, simply by purchasing all its hydraulic 

and cold air conditioning line needs from a single 

supplier, HANSA-FLEX. 

you're Never FAr FroM A 

HANSA-FLeX AGeNCy 

the cold air conditioning equipment is available in all 

HANSA-FLEX agencies. A replacement part can often 

be made here in a few minutes. the entire logistics 

of the partnership with OEMs is controlled here. 

As a result, the customer's contact person is never 

far away. this ensures close contact and is the best 

basis for cooperation with the purpose of ensuring 

customer satisfaction in all situations. the full range 

of services now offered in the cold air conditioning 

sector is described in the new HANSA-FLEX brochure, 

"Air-condition“, which is available for ordering now. 

Air CoNditioNiNG teCHNoLoGy FroM HANSA-FLeX is 

based on proven multipurpose coolant hoses with connectors 

and fittings made from aluminium or steel. they surpass all 

specifications that currently apply for diffusion and effusion 

values in the air conditioning industry. 




29

News 38th VDBUM Seminar 

38th VDBUM seminar in Braunlage 

The 38th VDBUM seminar series was held from March 3 to 7 in Braunlage. Once again, it turned into a rendezvous for specialists from the 

fields of construction machine technology, construction process technology, and the building industry itself. And this year too, a highquality 

technical agenda was on offer. 

On Wednesday, HANSA-FLEX delivered a presentation 

entitled "Hydraulic line equipment 

– from real life, for real life". The seminar 

was led by Helmut Wetteborn (an employee of 

HANSA-FLEX and author of the technical reference 

book "Hydraulische Leitungstechnik" (Hydraulic line 

equipment) and Ulrich Hielscher (a trainer with the 

IHA – International Hydraulics Academy). Both presenters 

are highly respected professionals in their 

fields, and their discussion was correspondingly well 

attended. 

The presentation also included a short film about 

the XWORLD Tour, which HANSA-FLEX is sponsoring 

at the moment (www.xworld.cc). All those who attended 

the VDBUM seminar also had the chance to 

win a place on stage 38 of the XWORLD tour (from 

Irkutsk to Omsk). HANSA-FLEX managing director 

Dieter H. Seidler announced the winner, Mr. Reinhard 

Biegert, a long-time member of VDBUM and sales 

manager for southern Germany with the LIEBHERR 

company. We offer our warmest congratulations and 

wish him much enjoyment on his adventure. 

Another high point of the event was a presentation 

by the popular mountaineer Reinhold Messner, who 

recounted some of his gripping experiences in the 

wilderness, and also talked about risk management 

– topics that are highly pertinent to a company's 

financial planning efforts, particularly in times of 

recession.– 

The Happy winner – from l. to r. Udo Kiesewalter (Deputy 

Chairman, VDBUM), Dieter-H. Seidler (Managing Director, 

HANSA-FLEX), Reinhard Biegert (Sales Manager for Southern 

Germany, LIEBHERR), Peter Guttenberger (Chairman, VDBUM) 

Photo: VDBUM 

Issue 

Anzeige 

Maßgefertigte Anzüge, Hosenanzüge 

und Kostüme aus reiner Schurwolle 

ab 298 Euro. 

Berlin · Bremen · Düsseldorf · Essen 

Frankfurt · Hamburg · Hannover 

Köln · Leipzig · Mannheim · München 

Nürnberg · Stuttgart · Wien 

Tel.: 040-380 385 0, www.dolzer.com 

30 DOLZER MASSKONFEKTIONÄRE. HANSA-FLEX Customers magazin 

KEIN LEBEN VON DER STANGE.

QuIZ | PrEvIEW FACtS & FiGureS 

WIn a Voucher from stadler 

SIMPLy ANSWEr tHE FOLLOWING QuEStION ANd A vOucHEr cOuLd BE yOurS 

In this issue, we are offering our readers multiple 

chances to win; we are giving away three gift certificates 

for the Stadler Zweirad center with values 

of 300, 200 and 100 Euro. they can be redeemed at 

any branch of Stadler cycle shops. 

Please send the answer in by Email to 

ma@hansa-flex.com or by post. Please do not forget to 

indicate your name and postal address. the deadline 

for entries is May 15th 2009. One entry per participant 

will be considered for the draw. terms and conditions 

apply for legal recourse and liability. A cash payment 

for the prize is not possible. Employees and members 

of HANSA-FLEX are excluded from participating. 

QueStioN: 

the regulations concerning safety and health 

handling hydraulic systems can be found 

where? 

A: BGr 237 

B: Brd 149 

c: BrG 526 

ANSWer editioN 02|2009 

C: Hydraulische Leitungstechnik 

Winner: P. Holst, Mainz 

facts & fIgures 

ANNIvErSAry 

tOtAL 

GErMANy 

April: 

Fulda, Germany Apr 1989 20 years 

May: 

Osnabrück, Germany May 1969 40 years 

Hasselt, Belgium May 1999 10 years 

Idar-Oberstein, Germany May 1999 10 years 

Panevėzys, Lithuania May 1999 10 years 

brANCHeS 

FLeXXPreSS 

331 

177 

220 119 

PreVIeW 06|2009 

tHE FOLLOWING tOPIcS WILL APPEAr IN tHE NEXt EdItION 

trAiNiNG CeNtre 

Opening of the new IHA building in dresden-Weixdorf 

trAde FAirS & eveNtS HANSA-FLEX at this year's Hannover trade fair 2009 

Work & LiFe 

Fine dust and ozone from printers and copiers charge the air in offices 

FASCiNAtioN teCHNoLoGy 

the cErN particle accelerator 

trAde FAirS & eveNtS 

HANSA-FLEX marketing trade fair and football tournament in Belgium 

NeWS 

Waldheim foundation: Opening of the new café 

did you kNoW...? 

Invention of oil hydraulics 


31

HALL 21, STAND D30 

HANNOVER TRADE FAIR 2009 

The entire spectrum of innovative technologies under one roof 

From April 20-24, 2009, no less than 13 leading international trade exhibitions will join 

under the same roof for the most important technology even in the world. The guiding 

themes are Industrial Automation, Energy Technologies, Drive and Fluid Technology, 

Mobility, Subcontracting, Future Technologies, and The Next Generation.

HYDRAULIKPRESSE april 2009, english issue - Hansa Flex

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