Figure 1: Band heaters. Source: Pelonis Technologies

Band heaters are made of nickel chrome resistance ribbon wire as the main heating element, use mica board or ceramic core as insulation material, and are insulated and covered by metal sheathing and rolled to the required band shape. They provide indirect heating around the surface areas of pipes, tubes and cylindrical vessels for many industrial applications.

Mica band heaters

Mica band heaters are widely used because of their versatile design and rugged construction characteristics. Mica bands have sheath temperature capabilities up to 800° F (425° C), have high watt densities and are easily customizable. They are very efficient and have a long life expectancy.

Ceramic band heaters

Ceramic band heaters heat large cylinders from inter­mediate to high temperatures of 1,600° F (870° C) without concerns of failures due to "hot-spotting" that conven­tional band heaters are susceptible to when used on large diameter surfaces.

Custom configurations

Mica and ceramic band heaters can be customized to include different voltages, power levels and sizesFigure 2: Mica and ceramic band heaters can be customized. Source: Pelonis Technologies based on application requirements. They can also be fitted with thermostats and thermocouples for optimal control and temperature regulation. Additional customization services include die-casting, injection molding, and the use of brass and stainless steel for high thermal conductivity solutions.

Features and specifications

• High thermal conductivity
• High watt density configurations
• High heat transfer efficiency
• Terminal or lead wire connections
• Thermostat and thermocouple options
• Rust and corrosion-resistant sheaths
• Easy installation
• Long life expectancy

Applications:

• Dies
• Injection and blow molding Figure 3: The heater band is made of a flexible, insulated material that houses a heating element. Pelonis Technologies
• Plastic extruders
• Drum heating
• Food service warming
• Hot runner bushing
• Pressure molding
• Cylinder heating
• Container pipe and tank heating

External mica band heaters

External mica band heaters are designed to wrap around the exterior surface of a cylindrical object such as a pipe or tank in order to heat its contents. The heater band is made of a flexible, insulated material that houses a heating element, which is typically a high-resistance wire wrapped around a mica core. The mica core provides insulation and heat transfer, while the external material provides protection from the environment. High-temperature capability up to 600° C. Custom voltages and sizes are available.

Industrial pipe heaters

Band heaters include medium-to-high temperature pipe heaters that have 500° C as a maximum working temperature. They provide long life and use less wattage (because of insulation) in plastics extrusion and injection molding applications. Pipe heaters are available with different terminal styles, are fully flexible, and can accommodate holes and cut-outs. Available voltages: 120 V, 240 V, 380 V and 450 V. Custom voltages and sizes are available.

Injection mold heaters

Injection mold heaters are used to heat the mold in an injection molding machine. Injection molding is a manufacturing process used to produce plastic parts in large quantities. The mold is typically made of metal and must be heated to a specific temperature to properly melt the plastic and allow it to flow into the mold. Available voltages: 110 V, 180 V, 220 V and 380 V, power load per square 3.5 W. Custom voltages and sizes are available.

Injection molding machine heaters

Injection molding machine heaters use mica plate (sheet) as a skeleton and insulating layer, supplemented by galvanized sheet or stainless steel sheet for support and protection. The Injection molding machine heater can be customized. Minimum diameter: 25 mm, maximum height: 300 mm, maximum operating temperature: 350° C. Available voltages: 220 V and 380 V, DC voltages are also available. Sizes can be customized.

Pipe band heaters

Pipe band heaters use nickel-chromium resistance wire as heating elements, and mica plates or ceramic cores as insulating material. The strip heaters produced are mica pipe band heaters, ceramic pipe band heaters and nozzle pipe band heaters. Inside medi­um-high temperature heaters up to 1,200° F, outside shell temperature: 350° F to 450° F, built-in ceramic fiber insulating material, stainless steel jacket. Minimum diameter: 60 mm, minimum width: 25.4 mm, thickness: 12 mm. Custom voltages and sizes are available.

Mica nozzle heaters

Mica nozzle heaters are used to heat the nozzles of injection molding machines and extrud­ers and are subjected to extremely high pressure to ensure high insulation, excellent heat exchange, no internal voids, and a perfectly smooth contact area for optimal and uniform heat transfer to each part. Features include faster heating and throughput for increased productivity, immediate response to temperature control, and resistance to contamination caused by plastic resin melt spillage. Custom voltages and sizes are available.

Injection molding heating elements

Injection molding heating elements are designed with spirally wound inner resistance coils evenly threaded through interlocking insulated ceramic “tiles.” The material's unique phys­ical characteristics can facilitate custom specifications with complex profiles and a smooth finish, and it also has a low cost and reduced lead time for production. Available voltages: 12 V to 480 V. Custom voltages and sizes are available.

Injection molding barrel heaters

Injection molding barrel heaters have a fast heat transfer, uniform heating and stable operation. They feature high power via a ceramic threading method (power is 0.5 ~ 1.5 times higher than that of ordinary types). They also provide fast heat dissipation, uniform heating, stable performance in high-temperature environments, and can be used in 300° C to 600° C environments for long periods. Custom voltages and sizes are available.

Injection molding machine band heaters

The charging barrel of injection molding machines generally use a band heater as the heat­ing device, which is installed outside the charging barrel and segmented by a thermocouple. When heat is conducted through the wall of the cylinder, high pressure is applied to the mol­ten plastic to provide a heat source for material plasticization so that it is injected and filled with a mold cavity and finally formed and cooled. Custom voltages and sizes are available.

Blow molding barrel electric band heaters

Blow molding barrel electric band heaters convert electrical energy into heat to heat objects. The temperature can reach more than 3,000° C and is easy to regulate by automatic temperature and remote control. Electric heating can directly generate heat inside the heated object and therefore has high thermal efficiency and a fast heating rate that results in overall uniform heating. Available voltage: 220 V. Custom voltages and sizes are available.

High temperature band heaters

High temperature band heaters are used in industrial applications that require high-temperature heating and provide uniform heating to cylindrical surfaces such as barrels, pipes and nozzles. They can be used in various industrial applications such as plastics processing, packaging and food processing. Available voltages: 110 V, 230 V, 380 V. Power 300 W to 1,200 W. Custom voltages and sizes are available.

High temperature ceramic band heaters

High temperature ceramic band heaters have fast heat transfer, are stable and have a long life expectancy. Available voltages: 12 V to 660 V, inner diameter of ring: ≥40 mm. Pow­er: The surface load can be designed to be 0.1-6W/cm2. Element: nickel-chromium wire and iron-chromium-aluminum wire. Appearance: terminal block, lead wire, ceramic terminal block, oil resin stainless steel junction box and iron plug. Custom voltages and sizes are avail­able.

Band heaters with thermostats

Band heaters with thermostats are made of mica plates and the outer surface is surrounded by stainless steel heating plates. Specifications, models, voltages and power of the heating rings vary. Material used includes mica board. Normal operating temperature can reach 800° C. The high-frequency porcelain strength magnetic base can withstand 15 A to 30 A cur­rent. Custom voltages and sizes are available.

Mica band heaters

Mica band heaters have good insulation performance and high temperature resistance. They use mica board (sheet) as the framework and insulation layer, supplemented by a stainless steel plate for support and protection, and can be made into plate, sheet, cylindri­cal and cone. Various types of heating devices such as circular shapes, cylindrical shapes and circle shapes are available. Power up to 1,000 W, mica band heaters can withstand temperature of 600° C. Custom voltages and sizes are available.

Ceramic band heaters

Ceramic band heaters are made of stainless steel and heat quickly up to 500° C in 30 seconds and with power from 50 W to 2,000 W. The resistance wire is rated with higher insulation and fire resistance and is formed by mechanical twisting. The shape can be customized, does not consume oxygen, does not oxidize and can emit far infrared rays and radiant heat, with emissivity as high as 91%. Custom voltages and sizes are available.

Ceramic band heaters with thermocouples

Ceramic band heaters with thermocouples are made by a ceramic wire threading method, which results in the power of the product of 0.5 to 1.5 times higher than other types. The outer cover is made of stainless steel and the middle is made of high-temperature thermal insulation cotton (aluminum silicate fiberboard) to prevent temperature leakage. They include high-frequency ceramics that have characteristics of fast heat transfer, high temperature, non-deformation and long life expectancy. Custom sizes and voltages are available.

Nozzle band heaters

Nozzle band heaters use nickel/chromium alloy as the heating element; the alloy wires are evenly distributed on the insulating mica layer so that the heating ring has a uniform heat distribution and reliable accuracy. The outer layer is a high-quality stainless steel metal sheath. The heating temperature can reach 450° C. Available voltage: 230 V. Custom voltag­es and sizes are available.

Nozzle band heaters with thermocouples

Nozzle band heaters are made of heating wire, mica (insulation), stainless steel (brass) and lead wires. The heating temperature can reach 450° C. They have a high pressure, very good insulation and provide good heat exchange. The copper per square centimeter of the sur­face heating coil has a high power density. Power standard density: 4.5W/cm2, maximum power density: 7 W/cm2. Custom sizes and voltages are available.

Stainless steel ceramic band heaters

Stainless steel ceramic band heaters are made of stainless steel material and the ceramic with higher insulation and fire resistance is put on a resistance wire and formed by mechanical twisting. They are easy to install, have high-temperature resistance, fast heat transfer and good insulation. Available voltages: 120 V, 220 V, 230 V, 240 V and 480 V. Custom voltages and sizes are available.

Stainless steel mica band heaters

Stainless steel mica band heaters are heating coils with uniform effective heat distribution and are made of a metal alloy with excellent thermal conductivity to ensure uniform temperature of the hot surface, and to eliminate the hot and cold spots of the equipment. They have advantages of long life, good heat performance, strong mechanical properties, corrosion resistance and magnetic field resistance. Custom voltages and sizes are available.

Extruder band heaters cast-in aluminum heaters

Cast-in aluminum band heaters are tubular electric heating elements. High-purity aluminum plates are used in casting production, which is changed from solid to liquid by a high-tem­perature furnace and then injected into a mold that has a heating tube installed, cooled and formed. The normal thickness of the cast aluminum heater is 20 mm and 25 mm and maximum operating temperature is 400° C to 500° C. Available voltages: 220 V /380V. Custom voltages and diameters are also available.

About Pelonis Technologies

Pelonis Technologies, Inc. ("PTI") is an innovator of air movement technologies, cooling fans and blowers, induction motors, and specialty heating products for commercial and industrial use.

The company offers high-quality products at competitive costs and employ flexible manufacturing techniques that enable Pelonis Technologies to respond to large and small-scale requirements. Their goal is to provide customers with significant value-added services, ready solutions or custom designs to meet their needs.

Innovation in motion

With over 25 years of product development and manufacturing experience, Pelonis Technologies' management team and engineers are committed to providing exceptional quality, product innovation and service at competitive pricing. Pelonis Technologies’ passion is to improve existing products and to develop new applications that benefit customers and their constantly changing needs. This dedication has enabled Pelonis Technologies to build long-term partnerships with their global customers. Valued Pelonis Technologies customers come from a variety of sectors, including medical equipment, aerospace and defense, heating and air-conditioning, automotive and appliances.

For additional information or for assistance with a band heater application, contact Pelonis Technologies at sales@pelonistech.com.

§