Electric Heaters Manufacturers and Suppliers

Electric Heaters

Electric heaters are devices designed to generate heat using electrical energy. Their widespread use extends across industries, commercial applications, and consumer products, with new configurations and applications emerging regularly. Many heater types share similarities, often leading to overlap in designations. For instance, band heaters and strip heaters are nearly identical, with band heaters being slightly more flexible and compact.

The vast selection of electric heaters includes many that cross categorical boundaries. Cartridge heaters, for example, sometimes function as immersion heaters but not always. Some heater names describe their purpose, such as drum heaters, while others indicate their design, like tubular heaters. Certain terms can be used interchangeably; air heaters and duct heaters both warm air in HVAC filters, yet a free-standing space heater can also be considered an air heater without being classified as a duct heater. Similarly, circulation heaters may be used to heat liquids in containment systems, while also applying to air-heating applications. Despite potential confusion in terminology, every heater type serves a vital role in industrial processes, commercial functions, or consumer products.

Electric heaters are employed in numerous industries for various functions, such as localized heating in machinery to aid in shaping or melting materials, heating liquid tanks, radiating warmth into the air, or maintaining substances in a molten state. Strip, band, cartridge, and air heaters frequently assist in these applications. In extrusion processes for metal, plastic, and rubber, friction alone may not generate enough heat to soften materials sufficiently. Supplemental heating ensures consistent plasticization, improving efficiency and product quality. Additionally, heat plays a fundamental role in industries such as packaging, foam fabricating, metal forming, and food processing. Cartridge heaters are commonly inserted into custom-sized holes within machinery to provide high-temperature, localized heat. Meanwhile, immersion and tubular heaters radiate warmth to heat liquids or air in water treatment plants, residential settings, and commercial buildings.

Electric heaters operate based on the principle of converting electrical energy into thermal energy. Electrons moving through a conductive medium collide with a resistor’s atomic particles, causing vibrations that manifest as heat. The component responsible for this process is the heating element, which can take various forms. Some heaters use simple coiled metal resistors, while others feature intricate configurations with ceramic insulators for better heat distribution and efficiency. Although heating elements alone can generate heat, most heaters incorporate insulation and a protective sheath—typically stainless steel, aluminum, or nickel—to enhance performance and extend lifespan.

Insulation plays a critical role in many electric heaters by retaining electrical energy until it can be released as heat. Ceramic is the most common insulation material, though other options like mineral, mica, and fiberglass exist, depending on application needs. Some radiating heaters use ceramic cores or complete heating elements to distribute heat via fans, as seen in space heaters, or through hot air duct systems, as with duct heaters.

Each electric heater must meet specific material, temperature, and power standards to ensure optimal performance. While non-electric heating methods such as coal, wood, gas, and water heating exist, electric heaters often provide greater energy efficiency. For example, electric water heaters are more environmentally friendly and economical than alternative heating methods. Safety is also a crucial factor when selecting an electric heater, as different models react uniquely to environmental conditions. Industry professionals carefully assess operating conditions and specific heating requirements before choosing the appropriate heater to ensure efficiency, longevity, and safety.

How Heaters Work

Heaters function by using high-resistance wire to convert electrical energy into heat. This process operates similarly to resistors found in home and industrial applications, where electrical current is obstructed, creating resistance that produces heat. Early heaters resembled light bulbs, where an electric current passed through a thin filament, generating both a bright glow and heat.

Most high-power incandescent bulbs are rated at 100 watts, yet they produce minimal heat for the user. To create more effective heating devices, manufacturers use high-resistance wires, such as Chromel, to form heating elements.

Heating elements are typically designed as coils or strips of wire, functioning much like a lamp filament but specifically engineered to generate substantial heat. These elements are commonly made from either iron-based or nickel-based materials. Nickel-based elements, such as nichrome or chromel, are alloys composed mainly of nickel and chromium. In nichrome, nickel constitutes approximately 80% of the alloy.

Nichrome is the preferred heating element material due to its high melting point—ranging between 1,400°F and 2,550°F—along with its resistance to oxidation, minimal thermal expansion, and optimal electrical resistance. As a result, it is widely used in industrial and household applications.

There are other forms of heat production elements used in industries and homes.

Bare Nickel-Chromium Wire (NiCr) or Ribbon

Can be used in a straight or coiled form and is commonly found in toasters and hair dryers.

Screen Printed Metal or Ceramic Tracks Deposited in Metal Plates Insulated with Ceramic

Frequently used in household appliances such as kettles.

Clarod Sealed Elements

 Nickel-chromium wires encased in a ceramic binder and sealed inside a metal shell. These elements, available as straight or curved rods, are commonly used in coffeemakers, ovens, and electric stoves.

Heat Lamps

 High-powered incandescent bulbs designed to emit infrared radiation instead of visible white light. These are often used in space heaters and food warmers.

PTC Ceramic

 A specialized ceramic that becomes highly resistive above a specific temperature threshold. This self-regulating property allows it to function as its own thermostat, preventing overheating.

In industries requiring extreme heat, such as metal and plastic melting, specialized materials like metal alloys, silicon carbide, and molybdenum disilicide are used.

Ceramics are the most commonly used insulation material, though other options such as mineral, mica, and fiberglass insulation are available depending on the heater’s specific application. Radiating electric heaters transfer heat using ceramic cores or complete heating elements, distributing warmth through airflow facilitated by fans, as seen in space heaters, or through hot air duct systems, as in duct heaters.

The History of Electric Heaters

The earliest forms of electric heaters relied on bulbs, with credit given to Thomas Edison for inventing the light bulb in 1880. However, heaters needed to be more durable and capable of generating greater heat for various applications. This required the use of a high-resistance wire, leading to a breakthrough by Albert Leroy Marsh, who developed chromel—the first alloys specifically designed for electric heaters. Also known as nichrome, chromel was up to 300 times stronger than other alloys available at the time.

Capable of reaching temperatures above 1,400°C while maintaining corrosion resistance, chromel revolutionized electrical engineering by making electric heaters more efficient and long-lasting.

In the early 1890s, General Electric, an American company, began producing the first commercial electric heaters. These heaters featured an elongated glass bulb and were manufactured by two companies, one of which was headed by Thomas Edison.

The UK and Heater Technology

In 1891, Herbert John Dowsing was pioneering electric cooking methods in the UK, designing an all-electric heating unit based on the long cylindrical bulb model. Though rudimentary, this design closely resembled modern heaters. The unit featured a copper backing to enhance heat radiation into the room, making Dowsing a key figure in the development of domestic heating in the UK.

By 1912, portable heating technology had gained traction. Charles Reginald Belling established his own company to manufacture heaters, producing early models that resembled table lamps.

Electric-Heaters in the 1900’s

Following World War II, radiant heating became increasingly popular. During this era, the bar heater—also known as the electric fire—was invented. These radiant heating units used bars of coiled wire that glowed orange when an electric current passed through them.

Most early electric heaters were portable, but they posed safety risks. If knocked over, they could start fires, and their exposed heating elements could burn inquisitive fingers. Today, bar heaters are still produced but now incorporate advanced safety standards to prevent such hazards.

By the 1960s, the growing demand for power led to the development of storage heaters. These units allowed both industrial and residential users to generate and store heat while consuming less electricity, improving efficiency and affordability.

Advancements in heating technology now focus on integrating smart technologies to control radiant heat production. Many industrial applications utilize remote controls and digital programming, improving energy efficiency, increasing portability, and enabling heaters to meet the demands of industries that require high-temperature heating solutions.

Ways to Enhance the Efficiency of Electric Heaters

Heating appliances are fundamental to industrial processes. Even before the Industrial Revolution, various heating systems were used to produce goods and support manufacturing operations. However, significant transformations in industrial heating technology primarily took place after the 1970s and 80s. During this period, electric heaters gradually replaced coal-powered systems, reducing reliance on wood and fossil fuels. This shift has played a crucial role in curbing pollution caused by industrial processes.

Induction Systems

Industries are increasingly adopting induction heating systems due to the numerous advantages they offer. While induction heating technology first emerged in industrial applications during the 1980s, its widespread adoption has only accelerated in the past decade. The surge in popularity is attributed to intelligent control systems and the potential for substantial energy cost savings.

Modern induction heaters operate using Eddy Current technology and conductive metals to generate the energy required for industrial processes. By integrating metal components with automated control panels, these systems ensure uniform heating while significantly reducing energy consumption. Incorporating an induction-based electric heater into a manufacturing process improves operational efficiency while cutting down on excess energy use.

Flame & Pollutant Reduction

Traditional heating methods using coal, wood, or petroleum inevitably contribute to pollution, releasing smog, vapor, smoke, chemicals, and harmful gases. In contrast, induction-based electric heaters eliminate these environmental concerns. These systems produce no flames, making them an attractive and eco-friendly heating solution for industrial applications.

Easy Heat Adjustment

Electric heating systems utilize electromagnetism to generate energy according to the specific industrial procedure. Operators can easily regulate the output temperature by adjusting the system controls, enabling precise and consistent heating tailored to process requirements.

Process Versatility

Induction-based electric heaters can be implemented in a wide range of industrial applications. Their adaptability allows for coil modifications to fit applications of various shapes and sizes. Additionally, a single induction heater can serve as the heating source for multiple processes, provided its capacity aligns with the application’s requirements.

Beyond these core advantages, electric heating devices can be custom-designed to meet specific operational needs. They are portable and compact, offering flexibility without compromising strength or heating performance. Regardless of size, induction heaters provide reliable and efficient heating solutions for modern industrial applications.

Important Tips to Consider for Electric Heater Maintenance

To maintain the efficiency and cost-effectiveness of industrial heating appliances, two essential factors must be addressed: proper installation and regular maintenance. Routine maintenance not only enhances heater performance but also reduces the risk of frequent repairs and replacements, ultimately lowering operational expenses.

The Department of Energy advises cleaning electric heaters twice a year, and many manufacturers recommend a six-month cleaning schedule for optimal performance. However, this may not be practical for heaters that operate continuously. Instead, maintenance routines should be determined based on the frequency and intensity of use.

Regular cleaning improves the performance of process machines and enhances the longevity of facility equipment. This is particularly important for applications that require consistent temperature control. Well-maintained heaters ensure stable and efficient heat delivery for industrial processes.

Whether using an electric heater, band heater, strip heater, or pipe heater, following these maintenance steps will help keep the equipment in optimal condition. These steps can also be applied to home heating systems.

Cut Off the Power Supply

Before cleaning, always turn off the heater to prevent electrical hazards. Use a voltmeter to confirm that no electricity is flowing to the device and that it has been completely powered down.

Remove the Thermostat Carefully

If the heater includes a thermostat, it must be removed before cleaning. Exercise caution when detaching the grill, ensuring that any mounting screws or knobs are loosened properly. Incorrect removal may cause damage to the unit.

Vacuum Clean the Heater

Use a vacuum cleaner to remove dust and debris from the heating unit. If a vacuum is unavailable, a hair dryer can be used to blow dirt from corners and crevices. Avoid using canned air, as it may introduce flammable particles into the system. Additionally, ensure that the heater’s fans remain stationary while cleaning to prevent unintended movement.

Gently Clean the Grill

Wash the grill with lukewarm, soapy water to eliminate accumulated dust and dirt. Allow it to soak for approximately 10 minutes to loosen stubborn debris before final cleaning.

Carefully Replace the Grill

Once the grill has dried completely, reinstall it to avoid electrical damage. Reattach the thermostat, secure any screws, and tighten them properly.

After reassembly, restore power to the heater and allow the thermostat to stabilize before switching it on. If unusual noises or irregular heating patterns occur, consult a professional electric heater repair service for further inspection.

Electric Heaters and Costs

In the development of electric heaters, whether for tankless water heaters or garage heating systems, manufacturers prioritize intermittent or partial-day operation to maximize energy efficiency. When integrated into industrial applications, these units offer a cost-effective heating solution.

Most modern heating units are designed with automatic shut-off functions, with the exception of certain air heater features, to minimize energy consumption. Their programmable capabilities and incorporation of infrared sensors further enhance energy savings, ensuring optimal performance while reducing overall power usage.

Different Types of Industrial Heaters

Electric heaters play a crucial role in both industrial and domestic settings, utilizing electric current to generate heat. These devices rely on an electrical resistor, operating on the principle of Joule Heating, where an electric current is converted into heat energy as it moves through a resistor. Most modern electric heaters use nichrome as their heating element wire. There are various types of electric heaters used across industries and households, each designed for specific applications.

 Immersion heaters are widely used in industries such as plastic and food processing. These heating applications are designed to heat liquids stored in large containers, reservoirs, or tanks. Operating on the principles of direct heat transfer, they enable quick and high-temperature adjustments, making them ideal for processes requiring rapid heating.

For applications involving fluids with different characteristics, electric heaters provide an optimal solution. Immersion heaters efficiently handle liquids of varying properties, reducing the need for frequent maintenance or repairs. They come in several varieties, including flanged, screw-plug, circulation, and side heaters. While earlier generations of immersion heaters used petroleum as fuel, modern versions primarily rely on electricity.

Pipe heaters are specifically designed to be installed within pipes with diameters of two to three inches. These compact devices perform effectively while remaining mounted inside a pipe. Ideal for applications requiring slow and low heating, they are commonly used for processing wax, tar, and highly corrosive materials.

Unlike immersion heaters, pipe heaters do not come into direct contact with the liquid they are heating. Instead, they utilize indirect heat transfer, where an internal element carries heat to the surrounding fluid. Because the heater does not interact directly with the liquid, it requires minimal maintenance, making it a reliable choice for long-term heating applications.

Cartridge heaters are designed for heating solid materials, particularly metals. These heaters operate at extremely high temperatures, as the melting and heating points of metals are significantly elevated. Typically affixed into a mold, cartridge heaters use thermocoupling to regulate their temperature precisely.

Known for their accuracy in heating and temperature control, cartridge heaters are frequently used in motor and hydraulic oil applications, gearboxes, and water-based heating processes. They are also widely employed in food production and laboratory settings. Heat is transferred through conductive wires, ensuring efficient and controlled thermal distribution.

Duct heaters are commonly integrated into airflow ventilation systems, comfort heating systems, and various process heating applications in commercial and industrial environments. Residential ovens also utilize this technology.

Duct heater motors are classified into three main categories: tubular, open coil, and finned tubular duct heaters. Each type is designed to meet specific heating requirements, ensuring optimal performance in both residential and industrial applications.

The Design of Heating Elements

Heat production elements are engineered for a wide range of applications, from small-scale heating devices like kettles to large-scale industrial units such as metal melting systems.

Engineers take into account up to 30 different factors when designing these units to ensure optimal performance. When electrical energy is transmitted through a heating element to warm air or heat water, its efficiency is influenced by current (measured in amps) and voltage (measured in watts for domestic use and kilowatts for industrial applications).

The performance of a heating element is determined by several variables, including its length, diameter, material composition, and operating temperature. Different types of elements require specific design considerations. For example, in coiled wire elements, parameters such as length, stretch, and pitch are crucial, whereas for ribbon elements, thickness, width, weight, and surface area play a critical role.

Heating elements do not function in isolation; they must be integrated into various appliances. The way an element interacts with its surrounding components, such as insulators, significantly impacts its efficiency and durability. The size and thickness of an element must align with the specific requirements of the appliance it powers. For instance, the heating element in a convection heater differs significantly from that of a soldering iron.

The expansion properties of the element material affect its stability when supported between insulators. Some materials may sag under prolonged use, leading to performance issues or mechanical failures. Engineers must carefully balance these factors to ensure that heating elements operate safely and efficiently without compromising durability or reliability.

Producing Heat in Industries

Electric heat production has been widely adopted across various industries due to its clean operation, as it does not produce fumes. One of its key advantages is the ability to apply heat precisely where it is needed. In industrial settings, there is typically a high concentration of power per unit volume and per unit area, making electric heating systems highly efficient. These units can be designed in any size, allowing them to be implemented in virtually any location within a processing plant. Their rapid response time enables high-speed cycling, facilitating mass production with improved efficiency.

 Although transferring electricity to the exact point of use can be relatively expensive, the efficiency of electric heating often outweighs these costs. Designing an industrial heating system begins with identifying the required temperature and heat output, followed by selecting the most effective method of heat transfer within the facility.

The most common heat transfer methods include:

• Conduction
• Convection
• Radiation
• Electric Fields
• Magnetic Fields

Industries employ different types of electric heaters depending on their specific needs. Some of the most widely used heating methods include:

• Resistance Heat Production
• Electric Arc Heat Production
• Induction Heat Production
• Dielectric Heat Production

In some applications, such as arc welding, heat is applied directly to the workpiece. In others, heat is generated by the heater and then transferred using one of the aforementioned methods. Industrial heating applications generally fall into three temperature categories:

• Low Temperature: Around 400°C, used in applications like drying and space heating.
• Medium Temperature: Around 1150°C, used for processes such as annealing and tempering.
• High Temperature: Above 1150°C, required for applications like smelting, welding, cutting, and brazing.

By selecting the appropriate heating method and temperature range, industries can optimize efficiency, reduce energy waste, and improve the quality of their manufacturing processes.​

Points to Consider When Selecting an Electric Heater for Industrial Use

Industrial heaters are powerful, precisely controlled devices with capabilities far beyond those used in residential applications. However, their high energy consumption contributes to production costs when implemented in manufacturing facilities. In some industries, entire processes depend on the performance of an electric heater in conjunction with other plant and facility equipment. Selecting the wrong heating appliance can significantly impact production quality and efficiency.

When choosing an industrial heating system, it is essential to consider the different types of heaters available.

Consider the following criteria when selecting an industrial heating system.

Types of Electric Heaters

Basically, there are four types of industrial heaters: electric, radiant, infrared, and petroleum. Out of these types, petroleum-based appliances produce the greatest level of pollutants and smoke, and the electric versions produce the lowest.

Electric Heaters

Electric heaters are the most commonly used in industrial, commercial, and residential settings. They are easy to install and operate, converting electrical energy into heat based on Joule’s theory of energy conversion. Most electric heaters feature a fan that circulates warm air, ensuring even distribution across the application area.

Radiant Heaters

Radiant heaters are ideal for applications that require simple, uniform heating. They work by radiating heat energy to any object within their range, with intensity decreasing as distance increases.

Infrared Heaters

Similar to radiant heaters, infrared heaters focus heat only on a designated area. Unlike other heaters, they do not use a fan, making them a noise-free option for industrial processes that require silent operation.

Petroleum-Based Heaters

These heaters use fuel sources such as gas, diesel, and kerosene. While effective in generating high levels of heat, they release a significant amount of pollutants, including chemicals, smoke, and smog, making them less environmentally friendly than electric alternatives.

Power Consumption

Given the high energy requirements of industrial heaters, it is essential to evaluate their power consumption or wattage before investing in a system. Engineers and suppliers should assess process equipment requirements to ensure that the chosen heater is both effective and energy-efficient. Investing in an energy-rated, high-efficiency heater can significantly reduce operational costs.

Safety Considerations

Worker and facility safety must be a top priority when selecting an industrial heater. Ideal safety features include an automatic tip-over switch, an overheat protection sensor, a cool-touch exterior housing, adjustable louvers for directional airflow, and built-in mobility features such as carrying handles and wheels. These design elements enhance usability while ensuring a safe working environment.

By carefully considering these factors, industries can select the most suitable heating system for their applications, ensuring efficiency, safety, and cost-effectiveness in their operations.

Choosing the Right Manufacturer

Many heater manufacturers produce both standard and custom heating solutions tailored to specific client requirements. Companies that offer custom heaters are often preferred, as they provide solutions designed to meet precise application needs.

When requesting a heating system, clients outline key specifications, including power and voltage requirements, the material of the heating element, and dimensions such as length, width, and diameter. Additional considerations include the heating element’s configuration—whether coiled or straight—as well as style and performance requirements. For example, hot water heaters generally require lower power than industrial heaters, which are designed for high-intensity applications. The overall cost of the unit is determined by these specifications, with more complex designs requiring advanced materials and technology.

A reputable manufacturer works closely with clients throughout the design process, ensuring that the final product aligns with their specific needs. By incorporating client input at every stage, from material selection to performance optimization, a manufacturer can create a heater that meets both functional and economic expectations.

Electric Heaters Images, Diagrams and Visual Concepts

Electric Heaters Types

Air Heaters

Electric heating systems designed to warm air within an enclosed space or work alongside a fan system to distribute heat throughout a building.

Band Heaters

Compact electric heaters that attach to pipes, tubes, and nozzles to apply heat in localized areas.

Cartridge Heaters

Small, high-intensity electric heaters inserted into machinery to provide targeted heat, commonly used in extrusion and thermoforming applications.

Ceramic Heaters

Electric heating devices featuring heat coils or other elements insulated with ceramic materials to enhance efficiency and heat retention.

Circulation Heaters

Electric heaters designed to warm circulating liquids or gases within an enclosed system, ensuring consistent temperature control.

Coil Heaters

Electric heaters distinguished by their coiled metal ribbon or wire heating elements, providing efficient heat distribution.

Drum Heaters

Electric heaters specifically designed to warm drum-stored substances, including industrial chemicals, water, and food products such as chocolate.

Duct Heaters

Electric heating elements integrated with HVAC systems to supply heat throughout a building’s ventilation network.

Foil Heaters

Versatile heaters used in various applications, including car battery warmers, incubators, heat exchangers, cabinets, defrosting systems, and wall or ceiling panels.

Immersion Heaters

Electric heating elements that function while fully submerged in liquids or some solids, efficiently warming large fluid volumes.

Kapton Heaters

Ultra-thin, lightweight electronic heaters using polyimide film to encase heating circuits, making them ideal for compact and flexible applications.

Process Heaters

Electric heaters used to treat raw materials with heat, playing a crucial role in surface treatment, shaping, and other industrial processes.

Silicone Heaters

Flexible, high-temperature heaters with internal wire elements encased in silicone rubber, capable of withstanding rapid temperature fluctuations, moisture, and chemicals.

Strip Heaters

Compact electric heaters designed to provide controlled heat to small areas, either through direct contact with equipment or by heating air in confined spaces.

Tubular Heaters

Electric heating elements with a tubular shape, designed for uniform heat distribution in industrial and commercial applications.

Electric Heater Terms

AC Current

Short for "alternating current," referring to the periodic reversal of electrical flow direction.

Ceramics

Non-metallic, inorganic, and often crystalline materials used as insulators in electric heaters.

Conduction

The process of heat transfer where vibrating atomic particles pass energy to adjacent particles upon contact. Conduction occurs in solids, liquids, and gases.

Convective Heat Transfer

 The movement of heat through a fluid, occurring as molecules transfer energy while in motion rather than through direct contact.

DC Current

Short for "direct current," referring to the unidirectional flow of electricity.

Desalination

The process of removing salt and other impurities from seawater to make it suitable for consumption or industrial use.

Ducts

Passageways that direct filtered or temperature-conditioned air throughout a space.

Electric Current

The flow of an electrical charge through a conductive medium.

Electro-Polish Finishing

 A process used to refine surfaces by removing unwanted material through electrochemical treatment.

Extrusion

A manufacturing process where raw materials such as plastic, metal, or elastomers are forced through a die to create continuous profiles.

Heat

The transfer of energy between objects, resulting from atomic particle collisions.

HVAC

Abbreviation for Heating, Ventilation, and Air Conditioning, referring to systems that regulate indoor temperature, airflow, and air quality.

Incoloy

A proprietary superalloy known for its strength and high resistance to corrosion and heat.

Insulation

A non-conductive material used to coat electrically conductive components, enhancing heater efficiency and protecting heating elements from damage.

Molding

A manufacturing process where raw materials like plastic, metal, or elastomers are shaped into non-continuous forms using molds.

NEMA Enclosures

Protective housings built to standards set by the National Electrical Manufacturers Association, designed to safeguard electrical equipment from environmental and mechanical damage.

Radiation

 The transmission of energy through electromagnetic waves or particles, including visible light, radio waves, and heat emitted by heating coils.

Thermostat

 A temperature control device combining a thermometer with mechanical or electronic components to regulate heating and cooling systems.

Watt

A unit of measurement for electrical power, indicating the rate at which energy is consumed or generated.