Problems on this page:
Flow rate falling
Hits OEE: Performance
Symptoms: The pump delivers less than its setting, and dosing or transfer takes longer.
Hose or tube worn and not recovering its shape
Replace the hose or tube and record how many hours it ran.
Suction line restricted or too long
Check the suction line for blockages, kinks and a closed valve.
Product viscosity higher than expected
Check the product temperature and the pump speed for that viscosity.
Rollers or shoes set with too little occlusion
Check the roller or shoe setting against the maker value for that hose.
Prevention: Flow checked by a timed volume or weight at the interval the process needs.
Hose or tube failing early
Hits OEE: Availability
Symptoms: Hoses burst or crack long before their expected life.
Pump running faster than the hose rating
Check the speed against the maker curve for continuous duty.
Hose material not compatible with the product
Check the chemical compatibility of the hose with the product and the cleaning chemicals.
Discharge pressure too high from a blocked line
Check the discharge line for closed valves and blockages.
Lubricant in the pump head low or wrong
Check the lubricant level and type in hose pumps that use it.
Prevention: Hose life recorded per pump so early failures stand out.
Dosing accuracy poor
Hits OEE: Quality
Symptoms: Doses vary from cycle to cycle in filling or dosing duty.
Tube not calibrated after replacement
Calibrate the dose after every tube change.
Tube fatigue changing the volume per turn
Replace tubes on a fixed run time before accuracy drifts.
Drip or suck-back at the nozzle
Check the anti-drip setting and the nozzle.
Air in the suction line
Check the suction for leaks and the supply level.
Prevention: Dose checked by weight at start-up and after each tube change.
Product leaking into the pump head
Hits OEE: Availability
Symptoms: Product is found in the pump casing after a hose failure.
Hose burst during running
Stop and isolate the pump, clean the head and work through the hose failure causes before refitting.
Leak detection sensor not fitted or not working
Test the leak sensor so a burst stops the pump at once.
Hose clamps or inserts loose
Check the hose connections at both ports.
Wrong hose size fitted
Check the hose part number against the pump.
Prevention: Leak detection tested on the maintenance plan.
Pulsation upsetting the process
Hits OEE: Quality
Symptoms: Flow pulses cause unstable readings or uneven filling downstream.
No pulsation dampener fitted
Fit a pulsation dampener or use a pump head with more rollers.
Dampener pre-charge wrong
Check the dampener pre-charge pressure.
Pipework flexing
Support the pipework.
Speed too low for smooth flow
Check whether a smaller hose at a higher speed would be smoother.
Prevention: Process flow trend reviewed after any pump change.
Drive or gearbox noise
Hits OEE: Availability
Symptoms: The drive makes noise or runs hot.
Gearbox oil low or old
Check the gearbox oil level and change it on schedule.
Roller bearings worn
Check the roller bearings during the hose change.
Overload from high discharge pressure
Check the discharge pressure.
Coupling misaligned
Check the alignment between motor and gearbox.
Prevention: Drive temperature and noise checked on a route.
Hose changes taking too long
Hits OEE: Performance
Symptoms: Each hose change takes long and stops the process.
Spare hoses not kept at the pump
Keep a spare hose and the right lubricant at each pump.
No written method
Write the hose change method with photos.
Lubricant drained and refilled slowly
Use the drain and fill points the maker provides.
Hose changes not planned
Plan hose changes by run hours, not by failure.
Prevention: Hose change time recorded.
Cleaning not effective
Hits OEE: Quality
Symptoms: Residue or microbial results after cleaning fail.
Pump run too slowly during cleaning
Run the pump at the cleaning speed so the cleaning solution reaches the right velocity.
Hose material absorbing product
Check the hose material for the product.
Dead areas at the connections
Check the hose connections for gaps where product collects.
Cleaning chemicals attacking the hose
Check chemical compatibility with the hose supplier.
Prevention: Cleaning results reviewed after each clean.
Guidance only. Always follow lockout/tagout and your site's safe-work procedures, and verify against OEM manuals before acting.
Related equipment guides: metering pump · progressive cavity pump · centrifugal pump · filling machine · air-operated diaphragm pump
Stop the same fault coming back
Recurring peristaltic pump stops usually trace to a cause you cannot see by hand. The partner we recommend is Fabrico: it tracks OEE and downtime live from PLCs, IoT sensors or AI cameras; where cameras are fitted, the video of a stop sits next to its machine data so the cause can be reviewed; and a technician opens the work order from the stop in the same system. Data is hosted in the AWS EU region, and Fabrico and the company behind it hold ISO/IEC 27001, ISO/IEC 20000-1 and ISO 9001.
Book a Fabrico demo
The directory stays free.
Related tools: full troubleshooting directory · OEE calculator · downtime cost · MTBF / MTTR · glossary
Methods that cut recurring stops: the six big losses · root cause analysis · preventive vs predictive maintenance · TPM · SMED & changeover