Defined heat output with resistance wire technology
Wire Heating Elements are based on "classic" resistance wire heating technology and are characterized by their high power output, geometric flexibility and durability. The different types of Wire Heating Elements - such as tubular heaters, cartridge heaters, flat heaters or immersion heaters - represent the great variety of our customers’ heating applications. Wire Heating Elements can be used for heating liquids, solids and gases - almost everything that requires high temperatures. The application possibilities of Wire Heating Elements are nearly unlimited and cover almost all industrial sectors as they are individually designed for each customer.
Defined heat output due to resistance wire technology
Power according to customer specification
Operating voltage up to 500 V
Operating temperature up to 950 °C
Surface load up to 25 W/cm²
Industrial Wire Heating Elements
Tubular Heater
Tubular heating elements consist of a metal tube and a resistance heating wire embedded in magnesium oxide (MgO). The electrical heating elements offer flexible design and can be used for many different applications in plant and mechanical engineering applications, HVAC, or electric vehicle heating. High power density and installation advantages make this heater suitable for many heating requirements. Tubular heaters can be customized in terms of power, nominal voltage, bending, and fastening. Depending on the application, various tube sheath materials are available. In order to tailor the heater to your application requirement, please provide as much information as possible.
Immersion Heater
Immersion heaters are electrical screw-in heating elements for direct heating of liquids, gases, and viscous substances. An immersion heater consists of a blind flange or screw head with several U-shaped tubular heating elements soldered into it. On request, they can be equipped with a temperature limiter or a protective cover. Immersion heaters are frequently used in plant and mechanical engineering or laboratory and medical applications. For immersion heaters, we recommend the use of overheating protection, as a dry run can cause high temperatures at the heating element.
Micanite Heating Elements
Micanite heating elements are electrical contact heaters and consist of a Micanite winding part and a heating conductor. For electrical insulation, the winding part is fixed between two Micanite plates and covered with a steel sheet for additional mechanical protection. Micanite is a material with high temperature stability for electrical insulation. Micanite heating elements are available in various shapes depending on the application and are usually pressed against the body from the outside or fastened via the existing fixing holes. They can be designed as flat or tubular heating elements. We recommend thermal insulation towards the non-heated side of the heater.
Aluminum Heating Plate
Heating plates are flat, mostly rectangular, solid contact heaters made of aluminum with precisely positioned cast-in tubular heating elements. The surface can be machined or ground to size according to customer requirements. Further, the plate’s contours, mounting, connection sockets, and coating can be specified individually. The design and construction of heating plates require great expertise, which is why we offer to take care of the complete construction process. E.g., it is particularly important to design a favorable heating element layout to achieve optimum heat distribution. With the help of CAD-based simulations, basic functions of the heating plate in the customer application - such as heating capacity and estimated surface temperature - can be tested in advance.
Ceramic Cartridge Heaters
Ceramic cartridge heaters consist of a ceramic multi-hole tube into which a heating coil made of wound wire is threaded. The top and bottom of the cartridge heater can be designed with increased thickness to provide more power. Ceramic cartridges are often used in plant and mechanical engineering applications such as tools or presses. They are suitable for all applications that require precise fitting, e.g. drill holes. It is important to ensure electrical insulation of the cartridge base, e.g. using Micanite discs. For installation, we recommend a sufficiently large drill hole diameter (cartridge diameter + 2 mm), as well as a clean, oil- and grease-free drill hole to ensure smooth and long-lasting operation.
Metal Cartridge Heaters
Metal cartridge heaters feature compact size with high power density and are used for direct or indirect heating of oil, alkaline solutions or tools. They consist of a metal tube and a heating conductor wound on a soft ceramic winding element, surrounded by magnesium oxide (MgO) for electrical insulation. High-performance cartridge heaters are highly compressed and ground to size in order to ensure a fit installation and thus optimum heat dissipation. They achieve a surface load of up to 25 W/cm². Alternatively, metal cartridge heaters with a similar construction such as ceramic cartridge heaters are available. They are installed in a metal tube with optionally vibrated MgO and achieve a surface load of up 4 W/cm².
Open Coil Air Heaters
Open coil air heaters are electrical heating systems based on patented wire heating technology for the dynamic heating of large air volumes. They consist of a sheet metal frame with several identical wound heating elements. These are manufactured in a patented process, in which a flat heating conductor is wound upright on a Micanite carrier. This design enables optimum heat transfer to the air flow. Thanks to the large number of wound heating elements, the air heaters can be designed flexibly in terms of dimensions and power output. Open coil air heaters are compact in size for easy and space-saving integration into customer applications. On customer request, they can be equipped with a temperature limiter (automatic or manual reset). For overheat protection, we highly recommend the installation of a temperature fuse in the end application.
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