Cartridge Heaters

High Watt Density Cartridge Heaters

Elmec is a leading high density cartridge heater manufacturer, employing cutting-edge technology and top-quality raw materials in the manufacturing process. Our advanced heaters are designed to deliver high wattage in compact spaces, making them ideal for demanding applications in industries such as Plastic Processing, Printing, Packaging, and Automobiles, where heavy vibrations are common.

Our commitment to quality is evident in the vibration-proof construction of our cartridge heaters, ensuring excellent reliability even in heavy-duty working conditions. Elmec’s heaters undergo a meticulous manufacturing process, guaranteeing durability and consistent performance.

The key to achieving optimal results lies in the correct installation of our cartridge heaters. The precise fit of the heater in the designated hole promotes efficient heat exchange between the heater surfaces and the material being heated. This not only enhances heater lifespan but also minimizes energy loss, contributing to cost-effective and sustainable operations.

Choose Elmec for high-density cartridge heaters that combine advanced technology, quality materials, and reliable manufacturing processes to meet the rigorous demands of various industries.

Technical specifications

High Watt Density Cartridge Heaters With Built In Thermocouple

Cartridge heaters can be produced with built-in ‘J’ or ‘K’ type thermocouples to provide heat control to increase heater life and to save energy

  • The junction at the bottom, ungrounded suitable to avoid disturbances to sensitive controllers.
  • The junction at the center gives a faster response. The control of the heat transfer in the application is possible.

Types Of Thermocouple

Code Positive Colour Negative Colour Temperature Range
J Iron (+) White Constantan (-) Red -20°C to + 750°C
K Chromel (+) Yellow Alumel (-) Red -20°C to + 1260°C

Terminal Lead Option

Right Angle Type

Straight Type

TOLERANCE
Diameter – 0.02 to – 0.08 mm
Length   Up to 100mm + 2mm
    Over 100mm + 1% to 3%
Wattage – 10% to + 5% (+ 5% available upon request)
Resistance + 10% to – 5% (+ 5% available upon request) Maximum working temperature allowed on sheath 750°C
MAXIMUM RECOMMENDED SURFACE LOAD
High Watt Density Max.150 W/Sq.inch Max. 25W/Sq.cm
Medium Watt Density Max. 65 W/Sq.inch Max. 10W/Sq.cm
Low Watt Density Max. 25W/Sq.inch Max. 4W/Sq.cm

Watt Density Vs Fit Size For Cartridge Heaters

Operating temperature of the heater and fit size are major factors in determining the life expectancy of cartridge heaters. Select the closest possible fit size for installing cartridge heaters for heating metal parts ref Fig-1 and Fig-2.

HOLE TOLERANCE
< 80mm length + 0.1 mm
81 to 200mm length + 0.15mm
 > 201 mm length + 0.2mm
Hole tolerance H7 up to 20W/Sq.cm
For higher load press fitting is required
Fit = Max.hole diameter – Min.heater diamete
Example
Heater Dia 15.8 (Maximum Tolerance – 0.08mm)
Hole Dia 15.9
Clearance 15.9 – 15.72 (15.8-0.08mm=15.72) = 0.18mm
We recommend tightest possible fit.

High Watt Density Cartridge Heaters Are Available In The Following Diameters

Metric Sizes Ømm 5 6.5 8 10 12.5 16 20 22 25
Inch Sizes Ømm 3/16 1/4 5/16 3/8 1/2 5/8 3/4 7/8 1
  • Standard Cable length – Fibreglass cable 300mm long.
  • We also manufacture any non-standard Diameter; Length & Terminal lead option as per customers’ requirement.
  • Wherever there is a requirement of high watts in less space.

APPLICATIONS

 
Plastic Processing MachineriesShoe Machinery
Injection Moulding MachinePackaging Equipment
Blow Moulding MachineMoulds & Dies
Plastic Extruder & Extrusion DiesRubber Industry
Hot Runner MouldsChemical Industry
Hot StampingHeating Liquids
Food ProcessingPower Plants
Medical EquipmentAutomobile Industries and many more applications.

Advantages

  • High watt density cartridge heaters make it possible to have high watts in less space without sacrificing a lifetime.
  • Proof against shock and vibration.
  • Excellent heat transfer.
  • Maximum operating temperature 1400°F (750°C) on the heater surface.
  • Our heaters are cylindrically ground to have better surface contact and minimum hole tolerance.
  • Leakproof Tig welded end cap prevents heater contamination due to the entry of any foreign materials.

Installation Recommendation

  • The tightest possible fit is recommended
  • Prevent damages to the hole surface while removing the heater.
  • Excellent heat transfer.
  • For easy fitting and removing the heater and to improve heater conductivity, a very thin layer of assembly get should be used on the heater surface and should not be in contact with cables to avoid short circuit.   Protect cables from physical damage, excess temperature and excess flexing etc.
  • Protect cables from physical damage, excess temperature and excess flexing etc.
  • Use suitable temperature controllers like PID controller with SCR, Thyristor, mercury relay or solid-state power controls to increase the heater life.
  • The sensor should be placed as close as possible to the heater (15mm).
  • Use largest possible number of heaters to reduce watt densities.