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Custom Industrial Process Heater Design

Hi-Watt carries many stock heater types available for same-day shipment, but some applications may require customized designs. As a turnkey supplier, Hi-Watt has the resources and expertise needed to design custom heaters in-house. Our custom industrial process heater designs have proven to increase productivity, reduce scrap rates, and ensure product quality in a variety of industries, from military and defense to food and beverage.

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What can we design for you? Contact us today, and our team will aim to provide a response same-day.

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Please describe your process heating application or thermal system challenge you’re experiencing.

What We Design

Hi-Watt configures industrial heaters from flexible blankets to immersion models, and partners with trusted brands, including Watlow and Tempco. All heaters are customized to meet application requirements.

Cartridge

Cartridge

  • Custom Diameters & Lengths
  • Split-Sheathed Designs
  • Distributed Wattage
  • Embedded Thermocouples
  • Moisture-Resistant Seals
  • Straight, Right Angle, & Side Lead Exits
  • Hot or Cool Tips
  • Direct Installation Into Drilled Holes

Band

Band

  • Clamps Around Cylindrical Surfaces
  • Mica, Ceramic, & Mineral-Insulated Configurations
  • One-, Two-, & Multi-Construction
  • Cutouts & Holes for Sensors & Nozzles
  • Multiple Diameters, Widths, & Terminal Locations

Nozzle

Nozzle

  • Designed for Injection Molding Nozzles
  • Integrated Cartridge-Style Elements
  • Coil, Band, & Cast Styles
  • Customizable Inside Diameter & Length
  • Round, Square, & Rectangular Profiles
  • Distributed Wattage
  • Integrated Thermocouples
  • Configurable Lead Exit Direction
  • Brass or Stainless Steel Jackets

Duct/Air

Duct/Air

  • Sized to the Duct Opening
  • Open Coil, Finned Tubular, & Tubular Element Options
  • NEMA Enclosures
  • Built-in Control Panels
  • Airflow Switches
  • Staging Steps
  • High-Limit Cutouts
  • Flange or Slip-in Mounting Configurations

Infrared

Infrared

  • Fast, Non-Contact Surface Heating
  • Quartz, Ceramic, & Metal-Sheath Options
  • Multiple Panel Sizes & Shapes
  • Reflector Designs
  • Zone Control
  • Integrated Pyrometers

Cable & Hose

Cable & Hose

  • Flexible
  • Ideal for Freeze Protection Applications
  • Made to Custom Length
  • Fixed Watt or Self-Regulating Cables
  • Silicone, Fiberglass, & PTFE Insulation Options
  • Temperature Ratings & End Fittings Matched to the Line Being Heated
  • Built-in Sensors
  • Overjackets & Insulated Jackets

Flexible

Flexible

  • For Use on Irregular or Flat Surfaces
  • Custom Contours & Shapes
  • Cutouts & Holes
  • PSA Adhesive Options

Strip

Strip

  • Bolted to Flat Surfaces
  • Customizable Widths, Lengths, & Thicknesses
  • Straight, Finned, & Mineral-Insulated Design Options
  • Hole, Slot, Clamp, & Bracket Mounting
  • Multiple Terminal Locations

Immersion

Immersion

  • Made for Fluid Applications
  • Screw-Plug, Flange, & Over-the-Side Models
  • Customizable Fitting Sizes, Flange Sizes, Pressure Class, Immersed Length, & Sheath Material
  • General Purpose, Moisture-Resistant, & Explosion-Proof Enclosures
  • Integrated Thermostats or Thermowells

Circulation

Circulation

  • Inline Heaters for Environmental Chambers or Closed Loop Systems
  • Customizable Vessel Size, Material, Pressure Rating, Inlet & Outlet Sizes, & Orientation
  • Optional Baffles, Insulation, Drains, Vents, Flow Switches, & Thermocouples

Tubular

Tubular

  • Bent to Any Shape
  • Customizable Sheath Diameter & Material
  • Sealed Terminals
  • Finned Tubular Options for Air Heating

Common Features


Multi-Zone Heating


Staged Heating


Thermocouple Integration


Weatherproofing


Explosion-Proof Enclosures


Hazardous Use Designs


Ra-Rated Surfaces

Additional Capabilities

  • UL 508A-Compliant Panels
  • Sensor Configuration & Installation Guidance
  • Control System Engineering & Tuning
  • Retrofit Assistance
  • Process Heater Sizing
  • Remote Troubleshooting
  • Thermal System Assessments
  • Field Repairs & Calibrations

Benefits of Working With Hi-Watt

  • Custom Turnkey Solutions
  • Responsive, Same-Day Communication
  • Fast Turnaround
  • Product Training
  • Post-Sales Support

Brand Partners

Watlow Logo
Nexthermal logo
Chromalox Logo
BriskHeat Logo
Tempco Logo

See Our Impact

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FAQs

Hi-Watt’s in-house engineers review your application requirements, including:

  • Operating temperature
  • Environmental considerations, including exposure to moisture, caustic or corrosive materials, and UV rays
  • The surface being heated
  • The material(s) being heated
  • Installation location
  • Existing electrical supply
  • Certification requirements

Too high or low watt density is one of the most common issues we see when we’re assessing a thermal system. Instead of calculating watt density on your own, contact our application specialists today at (855) 467-5628. Our team can help you determine the required watt density for the surface area you’re heating.

Industrial heaters come in a range of design configurations, including band, immersion, and circulation. The right style primarily comes down to what you’re heating (is it a vat of liquid, an entire tank, an area of a room, glass materials, a platen, etc.)

Yes. Hi-Watt can incorporate thermocouples and RTD sensors into heater designs, based on application requirements.

Yes. Hi-Watt frequently supports retrofits. We can perform an assessment of your existing controls system to determine heater compatibility.

The timeline of a custom heater project varies based on part availability and project complexity. When you contact us, provide a desired timeline and we will determine project feasibility.

Talk to the experts!

Have questions? Our dedicated sales team is here to help! With a track record of addressing 95% of inside sales quoting requests within 3 hours, trust our experts to provide timely and comprehensive assistance.

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