National Plastics and Rubber’s simple clamp that’s saving mines from costly downtime.
On a bustling mine site, where every piece of machinery is used industriously, one quiet workhorse can go unnoticed – despite often carrying the weight of the operation: the hydraulic hose.
These pressurised lines deliver the power that keeps heavy equipment running. Yet despite their critical role, they’re also one of the most vulnerable points on site.
But what if one small, smart clamp could transform the way they are protected?
That’s exactly what the HoseMate from National Plastics and Rubber (NPR) is doing by delivering a surprisingly simple, purpose-built solution to a problem that costs businesses time, money and safety every day.
Industry data shows, hose failures are the third most common cause of mobile plant breakdowns and, in most cases, these failures are not caused by internal pressure or faulty components, but by something far more preventable – external abrasion.
Whether caused by sharp edges, flat surfaces, hose-on-hose contact, or moving mechanical parts, abrasion steadily weakens the integrity of hydraulic lines until a failure becomes inevitable.
And when hoses burst, the consequences are immediate, including faltering productivity, an influx of repairs, and increased safety risks. In high-pressure operations, these events can lead to fluid injection injuries, environmental spills, and costly downtime.
Industries have long relied on a patchwork of traditional solutions to mitigate this risk.
But many of these options come with their own set of problems.
Some are expensive and wear out quickly. Others add unnecessary weight, limit flexibility or are incompatible with certain hose sizes.
A few even introduce the risk of electrical interference or mechanical failure.
HoseMate, on the other hand, offers a solution that is as practical as it is effective.
With no tools required, HoseMate is easy to install and, once in place, the unit holds hydraulic hoses securely and separately, preventing contact that leads to abrasion and failure. It is designed to ensure the optimum use of the hose is not compromised, and swift protection is delivered with minimal disruption.
Designed, tested and manufactured in Australia, this clamp is built from a durable polymer that has been developed specifically for the demands of heavy industry. It is UV-resistant for long-term use in outdoor and high-temperature environments, and is fire rated to V2 standards, which indicates the material is developed to self-extinguish within 30 seconds if it encounters a flame.
Before being put on the shelf, the entire unit undergoes rigorous tests to withstand vibration, extreme temperatures, chemical exposure and ongoing wear.
HoseMate begins reducing unplanned maintenance immediately after being fitted by preventing hose damage before it occurs and increases machine availability across the board.
Because HoseMate is built to outlast the hose itself, it can be removed and reused when the hose is replaced. At end-of-life, the clamp’s thermo polymer body can be ground down and used in new recycled products, reducing environmental impact and promoting more sustainable operations.
HoseMate is already helping teams on mine sites and mobile fleets take control of hose management, keeping lines in position, reducing entanglement and removing the guesswork from hydraulic protection.
This effectiveness has been tried and tested on the field.
A Tier 1 mining company in Western Australia was experiencing a common challenge with hose wear on its CAT 777 watercart suction and return lines. Despite standard clamps, hose damage occurred roughly every eight weeks, causing leaks and frequent downtime.
To resolve the challenge, a single HoseMate connection was installed at a key wear point during a planned service shutdown in May 2023. The installation took just a few minutes and cost about $30.
When inspected 10 months later, NPR found that the clamp remained firmly in place and prevented further damage – saving the site significant time and money. Conservative estimates put the savings from reduced maintenance and avoided downtime at over $40,000 for that one connection alone.
Beyond cost savings, the site highlighted the clamp’s flexibility and durability, noting how its design allowed the hoses to move naturally without sacrificing protection. By minimising the risk of hose blowouts and failure, HoseMate protected not just the equipment on the site but also the people who rely on it every day.
In an industry where uptime, safety and performance are constantly under pressure, this is just one example of how NPR’s solution stands out as an asset that does more with less.
Even as a small clamp, HoseMate has a big purpose: protecting hydraulic systems, improving safety, and helping operations run stronger, longer and smarter.
This feature appeared in the September-October edition of Safe to Work.