What Happens When You Use Off-the-Shelf Tubing in a Washdown Environment: Risks and How to Avoid Them

COR Manufacturing works with customers across food & beverage processing, pharmaceuticals and industrial manufacturing. These are industries where washdown environments are the norm, not the exception. Yet one of the most common and costly mistakes we see is the use of off-the-shelf tubing in applications that demand far more.

At first glance, standard tubing may appear adequate. It fits, it flows, and it is readily available. But once exposed to high-pressure washdowns, aggressive chemicals, temperature swings, and strict sanitation requirements, the risks quickly surface.

What is a Washdown Environment?

Washdown environments involve frequent cleaning using:

• High-pressure water
• Hot or cold temperature cycling
• Caustic cleaners, sanitizers, and disinfectants
• Repeated mechanical stress

These conditions are designed to protect hygiene and safety, but they are extremely demanding on tubing materials.

The Hidden Risks of Off-the-Shelf Tubing

1. Material Degradation

Standard tubing materials are not engineered for repeated exposure to chemicals, heat, or pressure. Over time, they can:

• • Soften or harden
  • Crack
  • Swell or leach additives

This degradation often goes unnoticed until failure occurs.

2. Loss of Sanitary Integrity

Off-the-shelf tubing may trap moisture, harbor bacteria, or degrade at the surface level. In regulated environments, this can result in:

• • Contamination risks
  • Failed audits
  • Product recalls

In food and beverage operations, even minor material breakdown can become a major compliance issue.

3. Reduced Pressure and Vacuum Performance

Washdowns introduce thermal shock and mechanical stress. Tubing not designed for these cycles may:

• • Collapse under vacuum
  • Balloon under pressure
  • Delaminate internally

The result is inconsistent flow and unplanned downtime.

4. Shortened Service Life and Higher Costs

While off-the-shelf tubing may save money upfront, frequent replacements, line stoppages, and maintenance quickly erase any initial savings.

How to Avoid These Failures

1. Choose Washdown Rated Materials

Tubing designed for washdown applications is formulated to withstand:

• • Repeated chemical exposure
  • Temperature extremes
  • High-pressure cleaning

Materials such as Silicone & Viton are built for these environments.

2. Match Tubing to the Cleaning Process

Not all washdowns are the same. Consider:

• • Type of chemicals used
  • Temperature range
  • Cleaning frequency
  • Pressure levels

Selecting tubing based on actual operating conditions, not assumptions, is critical.

3. Prioritize Compliance and Traceability

For regulated industries, tubing should meet applicable standards from organizations such as FDA and USDA where required. Documentation and material traceability matter just as much as performance.

4. Work with a Manufacturer, Not Just a Supplier

This is where COR Manufacturing adds value. Instead of forcing your application to fit a catalog product, COR works with customers to:

• • Specify the right material
  • Optimize wall thickness and reinforcement
  • Customize tubing for long-term reliability in harsh washdown environments

The Bottom Line

Washdown environments are unforgiving. Off-the-shelf tubing may look like a quick solution, but it often introduces hidden risks such as equipment failure, contamination, downtime, and higher long-term costs.

Right tubing is not just a component, it is a safeguard for your operation.

If your process involves routine washdowns, it is worth asking a simple question. Is your tubing designed to survive the environment it is in?

For more information, contact COR’s expert team now.