Industrial heaters are elements that convert electrical energy into heat through a resistance wire, heating a liquid, air, a mould or a product surface in machines and production processes. Continuous operation, high power, a sheath material that withstands the medium and mounting suited to the machine set these products apart from general-purpose heaters.
ResiVolt Rezistans manufactures industrial heating elements and heaters at İkitelli OSB in Başakşehir, İstanbul, in standard sizes or to the customer's technical drawing. The first step in choosing the right heater is to determine the medium into which the heat will be transferred; the groups below are organised according to this distinction.
Industrial Heaters by Medium
Liquid and Tank Heaters
Water, oil, thermal oil and chemical solutions are heated by immersing the heater directly in the fluid. Because heat passes into the fluid by conduction and natural convection, this group is among the most efficient applications. Boilers, process tanks, surface treatment baths and reactors are typical areas of use.
Selection note: The type of fluid determines the watt density and the sheath material: oil requires a low surface load, and corrosive baths require titanium, quartz or PTFE. The mounting method (screw plug, flanged or over-the-side) is chosen to suit the tank connection, and in explosive atmospheres an ATEX-compliant design is selected.
Products in this group
Product family: Liquid, Tank and Process Heaters
Air and Space Heaters
Air heaters heat the air passing through a duct or unit, carrying heat to drying, air conditioning and hot air processes. Because the air flow removes heat from the heater surface, the design is carried out together with the fan and flow control.
Selection note: Air flow rate, the required temperature rise and the duct cross-section determine the power. A finned coil body increases heat transfer; in dusty or fibrous environments the fin pitch is widened. A fan interlock and an over-temperature thermostat are mandatory safety devices.
Products in this group
Product family: Air and Space Heating Systems
Mould, Barrel and Surface Heaters
Heaters in this group transfer heat by contact to a solid part: an injection barrel, nozzle, mould plate, sealing jaw, drum or pipe surface. How well the heater fits the part directly determines heat transfer and service life.
Selection note: For cartridge heaters the bore tolerance is decisive; for band heaters, an exact fit to the diameter and the clamping force. Ceramic insulation is preferred at high temperatures, and silicone or cable heaters on curved and irregular surfaces. The sensor is placed at a point that represents the temperature of the heated part.
Products in this group
Product family: Mould and Barrel Heaters Heating Cables and Flex Surface Heaters
Quartz, Infrared and Furnace Heaters
In radiant heating, energy is transferred as infrared radiation without contact with the product. It provides fast response and non-contact heating in paint drying, thermoforming, print drying and surface treatment. In high-temperature furnaces, open coil, silicon carbide and MoSi₂ elements are used.
Selection note: The wavelength is chosen according to the absorption properties of the product: short-wave quartz heats quickly and intensely, while medium and long-wave ceramic heats more gently and evenly. The distance between heater and product and the use of reflectors affect efficiency; in furnaces, the working temperature and atmosphere determine the element type.
Products in this group
Product family: Quartz Infrared Heaters
Choosing an Industrial Heater
- Medium: Is the load a liquid, air or a solid part? Chemical composition, humidity and any explosive atmosphere are the starting point of the design.
- Temperature and power: Target temperature, heat-up time and heat losses determine the power required; the heater surface determines the permissible watt density.
- Sheath material: Stainless steel, Alloy 800, titanium, quartz and PTFE suit different temperature and corrosion conditions; one cannot be used in place of another.
- Mounting and connection: Screw plug, flanged, clamped or bore-fit mounting, and cable, terminal box or plug connection, are chosen to suit the machine.
- Control and sensor: A type J or K thermocouple or PT100 sensor, a thermostat or PID controller and a safety thermostat are planned together with the heater.
Custom Sizes and the Quotation Process
If your application cannot be met with standard products, we manufacture custom-designed heaters from a technical drawing, sample or photograph. Send the dimensions, power, voltage and operating conditions using the quote form; our engineer prepares the wattage calculation and material recommendation, and production starts after the dimension list has been approved.
Let us define the right solution for your project together
Contact us to determine the most suitable heater and industrial heating solution for your project. Our technical team is ready to offer the solution that best fits your requirements.