Special Heaters

What are special heaters?

Special heaters are components and complete heating modules adapted for unusual applications. They differ from standard universal heaters in that they are designed with consideration for the shape of the element, the type of medium, temperature requirements, and environmental conditions (e.g., hazardous areas, contact with chemicals, high humidity). Typical realizations include: band and strip heaters, insulated jackets, heating mats for substrates, cartridge heaters, ceramic elements, and modular solutions mounted on unusual surfaces.

Main types of special heaters

Band and strip heaters

Flexible bands quickly heat the walls of cylindrical tanks, pipes, or machine elements. Special versions are made of materials resistant to oils, chemicals, or high temperatures, and feature additional covers and connections adapted for industrial installations.

Insulated heating jackets and jackets

Jackets provide uniform surface heating and reduce heat loss thanks to integral insulation. They are used where process stability and energy efficiency are important — e.g., for heating tanks, molds, glands, or special process containers.

Heating mats and plates

Heating mats are easy to adapt to flat or slightly curved surfaces. They are used for heating workstations, mounting plates, heating tables, and technological floors, where controlled temperature distribution is required.

Cartridge heaters and modular high-temperature elements

Cartridge heaters are used in cylindrical holes and provide a fast, localized heat source. Special versions can be made with resistant covers, internal temperature sensors, or dedicated connectors for simple installation in the production line.

Dedicated and custom-made solutions

In many applications, "tailor-made" heaters are necessary — in terms of geometry, power, mounting method, and integration with the measurement system (thermocouples, PT100 sensors, controllers). Manufacturers offer versions made of special materials (e.g., corrosion-resistant alloys, silicone, PTFE) and with certificates allowing use in Ex zones.

Applications of special heaters

Special heaters are used where standard heating elements fail: in the chemical industry (reactive or viscous media), pharmacy (precise temperature control), food industry (consistency maintenance), accelerating injection and molding processes, heating measuring equipment, and in laboratory and research applications.

How to choose the right special heater?

Choosing the right solution requires analyzing several key parameters:

•        
• Type and properties of the medium — viscosity, thermal conductivity, chemical compatibility of materials.        
• Element geometry — contact surface, mounting access, shape of holes.        
• Power and power density — how many watts are needed per unit area to achieve the required heating rate.        
• Temperature range and accuracy — is precise regulation (±0.1°C) or only maintaining an approximate temperature needed.        
• Control method — thermostats, PID controllers, thermal protection, integration with the PLC system.        
• Environmental conditions — humidity, exposure to chemicals, Ex/ATEX zones.        
• Safety and certificates — declarations of conformity, IP rating, mechanical resistance.      

Advantages of investing in special heaters

•        
• Process optimization — faster achievement of process temperature and parameter stability.        
• Energy savings — better insulation and precise control can reduce electricity consumption.        
• Extended production line life — fewer downtimes caused by material temperature problems.        
• Process safety — dedicated safeguards and compliance with standards.      

FAQ — frequently asked questions

What distinguishes a special heater from a standard one?

A special heater is designed for specific application conditions and requirements: shape, medium, temperature, and safety requirements. Standard heaters are universal and will not always meet the specific needs of the process.

Can a heater be adapted for an Ex zone?

Yes — there are versions intended for explosive atmospheres with appropriate certificates. However, it is necessary to confirm compliance and installation conditions with a safety specialist.

What parameters should be prepared before requesting a quote?

Prepare information about: dimensions of the element to be heated, desired temperature and heating time, type of medium, mounting conditions, and requirements for control and safeguards.

Summary

Special heaters are a key element in optimizing many industrial processes. By matching the shape, power, and control method, you can achieve greater efficiency, lower energy consumption, and better production repeatability. Before purchasing, consult the technical requirements and ask for samples or assembly drawings from the supplier.