Cartridge Heaters

cartridge heatersOur selection of quality cartridge heaters (also known as rod heaters or insertion heaters offer exceptional durability and performance through advanced designs, superior materials and rigorous manufacturing standards. They provide corrosion resistance and efficient heat transfers. As dependable cartridge heaters suppliers our reliable brands are built for long life and more uniform temperatures.

Cartridge/insertion heater construction consists of an electric heating coil surrounded by a tube-shaped metal case. These industrial heaters come in a wide variety of diameters and lengths. They provide excellent vibration resistance.

Cartridge Heaters Suppliers

We supply industrial grade, standard rod heaters that offer: high temperature lead wires, high impact ceramic caps, precisely wound nickel-chromium resistance wire, stainless steel sheaths, and other features.

High-temperature sheaths and seals also guard against oxidation. Specialized designs, such as those found in split sheath heaters, allow for expansion, which works to maximize heat transfer. In the rod heater category, swaged heaters are compact designs for higher temperature operations. Swaging creates a low profile heater with operational efficiency and performance over a longer service life.

Standard Insertion Heater

  1. High Temperature Lead Wires for Temperatures up to 550° C.
  2. Stainless Steel Sheath can support up to 1000 F and Incolloy Sheath can support up to 1400° F.
  3. High Impact Ceramic Cap retards contamination and is suitable for high vibration applications. Deep holes in cap prevent fraying of leads when bent.
  4. Nickel-Chromium Resistance Wire for maximum heater life, evenly wound for even heat distribution.
  5. High Purity Magnesium Oxide fill selected for maximum dielectric strength and thermal conductivity, highly compacted for maximum heat transfer.
  6. 304 Stainless Steel Sheath for oxidation resistance in a wide variety of environments. 316 Stainless Steel.
  7. TIG Welded End Disc to prevent contamination and moisture absorption

Split Sheath Cartridge Heater

Use a unique, patented split-sheath design that expands when energized to maximize heat transfer through greater contact with the wall of the bore. Better heat transfer means less power is consumed to maintain the set point temperature, reducing operating costs.

WattFlex Thermocouple

Custom Cartridge Heaters

Used for process heating, a rod heater is sometimes referred to as an insertion heater. This is because the unit is inserted into a specially drilled hole to heat metal parts or small areas. Each industrial rod heater will come in a specific watt density. Leads and voltages also vary between models. The equipment is utilized in these commercial applications:

  • Plastic molding
  • Food processing
  • Liquid processing

We have high-watt or medium-watt density rod heaters available. First-class materials and manufacturing are featured in our durable rod heaters for commercial applications. Our knowledgeable Hi-Watt team will help you locate the best heater for your needs, so call today.


What Is a Rod Heater?

A rod heater is a heating element designed for industrial use. The internal components are encased in a metal sheath made from stainless steel. The tubes contain a nickel-chromium heating coil wrapped in electrical insulation. They are made to fit tightly into holes created with standard drill bits.

These heaters typically have a standard electrical cable. Based on your needs, our skilled team at Hi-Watt can also create custom heaters designed with alternative electrical connections such as flange mounting, right-angle exit, fixing tab and more. Cartridge heaters come in a variety of sizes, wattages and ratings.

Types of rod heaters include:

  • Immersion
  • Insertion
  • Split Sheath
  • Custom

Applications

These heaters can create very high temperatures. They are the perfect heating element for high wattage industrial use. They are very versatile and are used in a wide variety of applications. Rod heaters can heat dies, molds and other metal once inserted into holes in the component, or they can be used to heat liquids or gases by immersion.

These heaters can also be used to minimize condensation in control panels or closed circuits by regulating the temperature. They can be used in transportation for aircraft, trains and trucks. Custom cartridges can even be used in vacuum atmospheres. Examples of the many other applications that use cartridge heaters include:

  • Engineering
  • Food manufacturing and production
  • Hot runner molds
  • Hot stamping processes
  • Laminating presses
  • Medical industry
  • Packaging applications
  • Railcars
  • Rubber or plastic molding
  • Scientific testing and research
  • Semi-conductors

How Do Rod Heaters Work?

A rod heater is comprised of a metal sheath that is sealed on one end, power pins, resistance coil wrapped around a ceramic core, electrical leads and insulation. An electrical connection between the resistance wire and power pins, also called Joule heating, is what supplies heat to the sheath. That heat is then conducted from the sheath to the gas, liquid or metal it is intended to warm.

Key Specifications

Key specifications of these heaters are the physical dimensions like diameter, length and fit, as well as electrical rating, maximum temperature range and watt density. Diameters range from 1/4″ to 3/4″ or 6.5mm to 16mm in metric sizes.

Fit, also an important specification particularly at high watt densities, is the difference between the minimum diameter of the heater and the maximum diameter of the hole. Rod heaters can withstand temperatures up to approximately 1400° F and up to 260 watts per square inch of heated surface area.

However, you are not confined to standard dimensions, wiring or sheathing. Our team can produce custom heaters to your specifications. Talk to us about your specific application, and we’ll help you choose the optimal configuration.

Considerations when Choosing

Many considerations will help determine the right heater for your applications. Among them are energy efficiency, wattage, temperature and physical environment.

Energy Efficiency

Energy efficiency is determined by the materials used inside the heater. In short, the higher the thermal conductivity, the faster the response. Energy efficiency also means that your heater will last longer using less energy.

Lead Wire

The type of lead wire that is best for your application is one that is robust enough to stand up to the temperatures being generated. Choosing the wrong lead could result in power outages. Heater failure could lead to equipment damage, production timeline impacts, substandard product quality or product loss.

Wattage

Choosing a higher wattage heater is recommended in high-production environments. Fast heating upon activation means a more efficient and dependable process.

Physical Environment

Are you heating gases, liquids or metal? Each environment brings challenges and requires particular specifications for corrosion-resistance, heat tolerance, humidity, etc. Talk to one of our experienced Hi-Watt team members for guidance on picking the right heater for your environment.

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