Is "Compression Set" destroying your bottom-layer inventory?
Storing industrial hose coils—whether hydraulic, PVC, or large-bore suction lines—is a logistical nightmare. Wood pallets break under the point-load of coils. Floor stacking leads to ovalization and permanent kinking of the bottom units. You need a solution that respects the Minimum Bend Radius while maximizing vertical density.
In the industrial hose and flexible ducting industry, the traditional method of "lacing" or pyramid stacking coils on the floor is a profit killer. While it eliminates the immediate cost of racking, it introduces significant long-term losses.
1. Material Yield Loss: When heavy rubber hoses are stacked 4-5 high directly on top of each other, the weight creates immense pressure on the bottom coils. This causes the hose to lose its roundness (ovalization). For reinforced high-pressure hoses, this deformation can compromise the structural integrity of the wire reinforcement, leading to immediate scrap or field failure.
2. The Accessibility Trap: If a customer orders a specific SKU that happens to be at the bottom of the stack, your warehouse team has to move dozens of heavy coils to reach it. This double-handling increases labor costs and the risk of back injuries.
Derack systems prevent crushing by bearing the load through the steel posts, not the hose itself.
Standard 40x48 inch pallets are useless for industrial hoses. A 3-inch suction hose might have a coil diameter of 60 inches or more. Placing these on undersized pallets leads to overhang, causing the hose to sag and develop permanent "memory" bends that make installation impossible for your customers.
Our custom size stack racks are engineered to match your specific coil geometry:
The Derack system converts your warehouse from "floor storage" to "cubic storage." By utilizing a metal post pallet system, you can safely stack coils 4 to 5 levels high.
Crucially, the weight of the upper racks is transferred through the vertical steel posts to the floor, bypassing the inventory entirely. The bottom coil experiences zero compression, ensuring that the product you ship is perfectly round and kink-free, just as it left the extruder.
Custom lengths available for straight lengths or large diameter coil storage.
Why handle loose coils multiple times? With our system, the hose comes off the production line directly onto the rack. A forklift can then move the entire unit load—containing multiple coils—to the curing area, the warehouse, or directly onto a flatbed truck for delivery.
This significantly reduces forklift travel time and eliminates the need for specialized "boom" attachments often used to spear coils, which can damage the inner liner.
Empty racks nest efficiently (see bottom right), reducing return freight costs in closed-loop supply chains.
Q1: Can these racks prevent "flat spotting" on soft PVC hoses?
Yes. Because the racks bear the load of the vertical stack, the bottom PVC coils are never subjected to the crushing weight of the layers above, eliminating flat spots and ovalization.
Q2: We store hoses outdoors. Will these racks rust?
We recommend our Hot-Dip Galvanized finish for outdoor hose yards. The zinc coating (>60 microns) provides self-healing corrosion protection, ensuring a lifespan of 10+ years even in rain and snow.
Q3: Can I customize the post height for different coil widths?
Absolutely. The posts are demountable and available in various lengths (e.g., 40", 60", 80"). You can swap posts to match the stack height of different hose SKUs, optimizing vertical space.
Q4: How many racks can be transported in a standard shipping container?
When empty, the posts are removed, and the bases nest together. This allows you to fit hundreds of empty units in a standard 40ft container, making return logistics highly economical.
Q5: What is the weight capacity per rack?
Our standard heavy-duty designs are rated for 1,000 kg to 1,500 kg (approx. 2,200 - 3,300 lbs) per rack, which is sufficient for even heavy steel-reinforced hydraulic hose coils.
