•   Explain your quality control procedures throughout the manufacturing process, from raw material inspection to final product testing.

    At Ocelflex, we uphold the highest standards of quality through a meticulous and well-structured approach. To ensure precision, consistency, and excellence in every product, we have invested in and continuously enhance our Ocelflex ERP IX system. This advanced system meticulously tracks and maintains quality records at every stage—from the receipt of raw materials to the final dispatch—ensuring complete traceability and accountability.

    By seamlessly integrating sales, design, production, quality control, dispatch, and customer support into a unified system, we have created a streamlined workflow that enhances efficiency and enables us to serve our customers with exceptional reliability.

    Our commitment to excellence extends to our state-of-the-art automated manufacturing facilities, where advanced expansion joint and flexible hose production machines ensure precision and consistency in every component we produce. Furthermore, each product undergoes rigorous testing, with every step meticulously documented to uphold our commitment to superior quality and performance.

•   Do you offer emergency manufacturing services for critical situations, and how can a request be activated?

    At Ocelflex, we understand that unexpected shutdowns and critical failures demand immediate solutions. Our advanced manufacturing capabilities, streamlined processes, and dedicated team allow us to respond to urgent requirements with precision, speed, and technical expertise. Over the years, we have successfully executed emergency manufacturing projects under extreme time constraints, ensuring minimal downtime for our clients. We have had some emergency manufacturing requests by clients globally as well as in India :

    Emergency Shutdown in Kuwait – 24 Axial Expansion Joints in 2 Days
A part of an oil plant in Kuwait experienced an emergency shutdown, requiring immediate replacement of 24 axial expansion joints of 550 NB size. These were Stainless Steel 316L multi-ply expansion joints, but within just 48 hours, we not only manufactured the joints but also ensured their dispatch along with all the quality documents, allowing the plant to resume operations without significant losses.

    Neglected Failure Due to Grain Boundary Cracks – One 52" & two 48" Axial Expansion Joints in 3 Days
When a power unit in India suffered an unexpected failure of its expansion joints due to grain boundary cracking in a furnace component, we acted swiftly. Within 3 days, we designed, manufactured (welded, punch formed, re-rolled, hydro tested), and dispatched 52-inch and 48-inch axial expansion joints, preventing further damage and restoring operational efficiency. The director of the plant and the plant engineer were highly impressed with our swift execution and technical expertise, personally thanking us for ensuring the plant's rapid recovery.

    Pharmaceutical Industry – 400 Stainless Steel Hose assemblies for COVID Response
During the COVID-19 crisis, a renowned pharmaceutical drug manufacturing unit in North India required 400 nos. stainless steel corrugated hoses with double braiding to maintain uninterrupted production. Lucky for us and the drug company, we had enough of the raw material and end fittings of the same specifications. Understanding the critical nature of the request, we expedited the process and ensured timely delivery, playing a key role in supporting essential drug manufacturing.

    Hospital Installation in Egypt – 1275 units of Stainless Steel 316L Hoses in 3 Days
A client in Egypt, responsible for supplying stainless steel hoses for a hospital installation, faced an urgent deadline. He was promised supply locally, but the local supplier produced inferior quality hoses. We manufactured and dispatched 1275 hoses each, in lots of 25 and 50 with different customized fittings ranging from bends and threaded fittings to flange fittings. We dispatched the material in two lots, first 700 in two days and the balance by the 4th day, ensuring their deadline was met and the project was not delayed.

    How to Request Emergency Manufacturing Services?
If you require urgent production due to plant shutdowns, equipment failures, or unforeseen circumstances, contact us immediately. Our team will evaluate the urgency, technical specifications, and feasibility, mobilizing resources to design, manufacture, and dispatch your required components in record time, ensuring that your operations never come to a standstill. Click the link below and select the Express Manufacturing!

EXPRESS MANUFACTURING

•   How are raw materials assessed, and how frequently is testing conducted?

    At Ocelflex, we maintain stringent quality control by ensuring that all raw materials entering our facility are either accompanied by a valid Material Test Certificate (MTC) or undergo in-house Positive Material Identification (PMI) testing upon arrival. No material is permitted into our production process without verification of its compliance with required specifications.

    This ensures that only materials meeting our exact standards proceed to the manufacturing stage. Additionally, we conduct dimensional evaluations and verify other mechanical characteristics such as tensile strength, elongation, and hardness where required.

    For clients requiring full traceability, we provide detailed MTCs for every product. Upon request, we can also supply third-party certified test reports, including NABL-accredited laboratory certifications or other approved testing lab reports, ensuring complete transparency and compliance with international quality standards.

•   What materials do you use for manufacturing hoses and expansion joints?

    1. Stainless Steel Corrugated Hoses
• Produced in SS 304, SS 316, and SS 321, offering excellent flexibility, high-temperature resistance, and corrosion protection.
• Available with Inconel construction for extreme temperature and aggressive media applications.
• Reinforced with stainless steel wire braiding in SS 304 or SS 316, ensuring superior pressure containment and mechanical durability.

    2. Expansion Joints & Bellows
• Metal Expansion Joints: Fabricated from SS 304, SS 316, SS 321, Inconel, Hastelloy, and Carbon Steel, selected based on operating conditions like pressure, temperature, and media compatibility.
• Rubber Expansion Joints: Manufactured in EPDM, Nitrile (NBR), Neoprene, and Viton, each suited for specific fluid and environmental resistance.
• Fabric Expansion Joints: Designed with high-performance composite materials, including PTFE-coated fabric, fiberglass, and aramid blends, providing resistance to extreme heat and chemical exposure.

    3. Composite Hoses
• Engineered using multi-layered thermoplastic films for superior chemical resistance and durability.
• Reinforced with galvanized steel or stainless steel wire helix, ensuring strength while maintaining flexibility.
• Inner layers can be customized in polypropylene, PTFE, or polyester, tailored for specific fluid compatibility.

    4. PTFE Hoses
• Manufactured from premium-grade PTFE – Teflon resin, ensuring non-stick properties and excellent chemical inertness.
• Reinforced with stainless steel SS 304 or SS 316 wire braiding, providing enhanced pressure performance and extended service life.

•   Which International Regulatory Requirements and Industry Standards Do Your Products Meet?

    At Ocelflex, we design, manufacture, and test our products in strict compliance with international standards, ensuring reliability, safety, and superior performance. Our adherence to global benchmarks guarantees pressure integrity, mechanical strength, and durability, meeting industry requirements for flexible solutions across various applications.

    Our stainless steel corrugated flexible hoses are designed and tested in accordance with ISO 10380 and BS 6501, which cover best practices for the manufacture, testing, and usage of metallic flexible hoses in industrial applications.

    Our composite hoses are manufactured following European regulatory standards, with EN 13765 applied for standard-duty and heavy-duty hoses and EN 13766 for specific LPG, LNG, or cryogenic transfer applications.

    We manufacture metallic and non-metallic expansion joints and bellows in compliance with EJMA, an industry-recognized standard for design, calculation, and testing, ensuring fatigue life, pressure stability, and high performance. We also manufacture expansion bellows conforming to ASME pressure vessel regulations.

•   What type and standard of end fittings and assemblies do you offer?

    Our hose and expansion joint end fittings and assemblies comply with internationally accepted standards, including ANSI Class 150, 300, 600, 900 (American standard), Table D, E, F (British standard), and PN 6, PN 10, PN 16, PN 20 (European standards).

    For vacuum applications, we adhere to KF flange standards. Additionally, pipes and flanges are manufactured in accordance with ASME B16.5 and B16.47, and we can drill flanges to Japanese standards JIS B2312, B2316, JIS 5K, and 10K.

    Our threaded connections are manufactured with precision according to common fluid and hydraulic fitting industry standards, including BSP, BSPT, NPT, UNF, and JIS.

    We also offer these fittings with a wide range of material such as Stainless Steel, Brass, Inconel, Duplex Steel, Nylon and PTFE.

•   Are Metal Expansion Joints and Metal Flexible Hoses the same product?

    Although metal expansion joints and metal flexible hoses may appear similar, they serve fundamentally different purposes. Understanding these differences is crucial in selecting the right product for your application.

    Construction Differences
Metal hoses are designed with annular or helical corrugations and typically consist of one to three plies, reinforced with one or two layers of stainless steel wire braid. This construction provides flexibility, pressure containment, and vibration absorption.
In contrast, metal expansion joints feature deep, low-pitch convolutions and are often manufactured using multi-ply stainless steel sheets. Depending on the application, they may be reinforced with tie rods, lugs, or gimbal slots to control movement.

    Functional Differences
Unless specifically designed otherwise, metal hoses are primarily used to absorb vibrations, misalignments, and higher internal pressures. On the other hand, metal expansion joints are engineered to accommodate axial, lateral, and angular movement, making them ideal for thermal expansion compensation in piping systems. Expansion joints typically operate at lower pressure ratings than metal hoses but are essential for preventing stress buildup in pipelines.

    Application & Installation
• Metal hoses are manufactured in long continuous lengths, making them ideal for fluid and gas transmission while offering flexibility and vibration damping.
• Expansion joints, however, are manufactured in shorter lengths (typically up to 400 mm) and are custom-designed for specific applications.
Installation also differs significantly:
• Metal hoses are general-purpose components that can be installed easily, even by personnel with minimal experience.
• Expansion joints require technical expertise for proper installation, as incorrect placement can lead to system failure due to excessive movement or misalignment.

    Size & Reinforcement
At Ocelflex, we manufacture:
• Metal hoses ranging from ¼ inch ID to 18 inches ID, complemented with stainless steel wire braiding for enhanced pressure resistance, vibration damping, and external protection.
• Metal expansion joints in much larger diameters, up to 60 inches ID, without an external covering unless specifically required for the application.

    By understanding these distinctions, you can select the right component for your system, ensuring efficiency, durability, and optimal performance.