Band Heater Buyers Guide

Before you begin the buying process for band heaters, there is some information you should be aware of. First, what are band heaters? Industrial band heaters are commonly used to heat cylinders such as barrels, pipes, or nozzles of injection molding and extruding machines. They are most often used in the plastics industry, however, other applications do apply. 

Thermal Corporation has been in business in Madison, Alabama since 1969. We design and manufacture band heaters right here in the United States to your custom specifications and they can be shipped to you quickly. To learn how to correctly measure your band heater, watch our video here. 

Types of Band Heaters

There are different types of band heaters for different solutions. Here are the four types of band heaters offered by Thermal Corporation. 

Mica Band Heaters

Mica Band Heaters are constructed by a resistance element being wound around mica, then insulated with mica on both sides of the element. A sheet of coated steel is then folded around the mica’s composite layers. The mica core is wound with wire and leads are attached. After the leads are attached, the outer sheaths are then applied and the band heater is then rolled and formed to desired diameter. 

Purchasing Information for Mica Band Heaters

Information we will need in order to fulfill your request includes, configuration (view this link https://www.thermalcorporation.com/all-mica-band-heater-configurations/), the diameter of the part you want to install the band heater on, the width of the heater, the length of the lead wires (if appropriate), and finally specify the wattage and voltage. For more information on placing an order with Thermal Corporation, click here.

Tips for Installing Mica Band Heaters

When replacing or installing a new mica band heater, make sure your barrel or nozzle’s surface is free of any material and clean. If there is a small rough spot or some type of foreign material on the barrel or nozzle, it can largely reduce the lifespan of your mica band heater because the small speck can cause an air gap, causing a ‘hot spot’. A air gap the size of 0.005″ on a typical 30 watts sq inch heater will cause that spot to run 250 degrees (F) hotter.

We recommend checking the heater after 15 minutes of operating time after initial installation or replacement. You should make it a priority to check the tightness of your mica band heater often. It’s as simple as re-tightening the strap or clamp mechanism. It will probably surprise you how much longer of a lifespan a mica band heater will have when re-tightened often.

The fewer holes in your mica band heater, the longer the lifespan. Each hole in a mica band heater is another street open for contamination. Not only that, you are adding to the delivery time and also the expense of your heater. If you are looking to attach a thermocouple or other accessory, you should consider purchasing a heater with a larger gap specifically to fit thermocouples. Another option to consider is purchasing two heaters instead of one if several holes are needed. For example: let’s say you are using a 6 inch wide heater that has several one inch holes. Instead, you can try using two heaters that are 2.5 inches wide.

Using the right parts is another essential part of getting the most out of your mica band heater’s lifespan. If you need post terminals on your mica band heater, be sure you are using high temperature ring terminals, because standard ring terminals can overheat easily, causing them to become brittle and possibly break. Thermal Corporation also offers high temperature wire and ring terminals on our accessories page.

 

The advantages of mica band heaters include: 

• High watt-density capabilities
• Reasonably high temperature capabilities- 700°F
• Good efficiency
• Good lifetime
• Low cost

           

Additional Options for Mica Band Heaters 

• • Holes/Notches – Any reasonable size and location is available on custom made ceramic heaters. Contact us for assistance in determining feasibility.
  • Ground Wire – Can be added to most configurations for ceramic band heaters.
  • Thermocouple Adapter – Can be added to most configurations for ceramic band heaters.

• • Spring Clamps/Screws – Recommended for most large diameter applications, 10″ or greater, to ensure adequate clamping motion.

• • Strain Relief Spring – Goes over stainless steel overbraid (approximately 4” coverage from where leads exit). Available for Configurations 616, 617, 618, 619, 622, and 623.

• • Non-Standard Location of Leads – Leads or terminals can be located at reasonable places along the heater, for applications where standard connections may not be accessible. Contact us for more details.

• • Copper Elbow with Stainless Steel Hose – Available on some configurations. When ordering, specify orientation of elbow to heater.

• • Copper Elbow with Stainless Steel Overbraid – Available on some configurations. When ordering, specify orientation of elbow to heater.

• • Terminal Box – Available for all configurations with post terminals. Contact us for more details.

• • 3-phase Power & Dual Voltage – Available on ceramic heaters with post terminals or leads. Minimum size restrictions may apply. Contact us for more details.

• • European Connector – Two-pole cup European plug available on most configurations. Minimum diameter and minimum width restrictions may apply. Contact us for more details.

Ceramic Band Heaters

Thermal Corporation’s ceramic band heaters are manufactured with a stainless steel covering that encloses the high quality ceramic knuckles. Coiled high temperature nickel-chromium element wire is run through these ceramic knuckles.

Purchasing Information for Ceramic Band Heaters

Before purchasing you should be aware of all of your configurations options (https://www.thermalcorporation.com/ceramic-band-heaters/). You can choose between one or two piece heaters, types of lead, post terminals, and type of closure. Information we will need in order to fulfill your request includes quantity, configuration, width (increments on half inches), inside diameter, wattage, voltage, lead length (if applicable) and any additional options – see below. For more information on placing an order with Thermal Corporation, click here. 

Additional Options for Ceramic Band Heaters

• • Holes/Notches – Any reasonable size and location is available on custom made ceramic heaters. Contact us for assistance in determining feasibility.
  • Ground Wire – Can be added to most configurations for ceramic band heaters.
  • Thermocouple Adapter – Can be added to most configurations for ceramic band heaters.

• • Spring Clamps/Screws – Recommended for most large diameter applications, 10″ or greater, to ensure adequate clamping motion.

• • Strain Relief Spring – Goes over stainless steel overbraid (approximately 4” coverage from where leads exit). Available for Configurations 616, 617, 618, 619, 622, and 623.

• • Non-Standard Location of Leads – Leads or terminals can be located at reasonable places along the heater, for applications where standard connections may not be accessible. Contact us for more details.

• • Copper Elbow with Stainless Steel Hose – Available on some configurations. When ordering, specify orientation of elbow to heater.

• • Copper Elbow with Stainless Steel Overbraid – Available on some configurations. When ordering, specify orientation of elbow to heater.

• • Terminal Box – Available for all configurations with post terminals. Contact us for more details.

• • 3-phase Power & Dual Voltage – Available on ceramic heaters with post terminals or leads. Minimum size restrictions may apply. Contact us for more details.

• • European Connector – Two-pole cup European plug available on most configurations. Minimum diameter and minimum width restrictions may apply. Contact us for more details.

The advantages of ceramic band heaters include: 

• Lower Operating Cost
• Longer Heater Life
• Higher Operating Temperatures
• Dual Heat Transfer
• Operator Comfort
• Flexibility

 

Rectangular Band Heaters

Thermal Corporation’s rectangular band heaters are a specific type of mica band heaters that are shaped into rectangular form and are two piece heaters. These types of band heaters are used for a dye or mold with a rectangular shape that a regular sized band heater won’t fit. They are constructed identically as mica band heaters, so the temperature rating remains at 700° F. There are three different configuration types: Configuration 403, 415, or 417. Each configuration has several different options to choose from. 

Purchasing Information

To purchase a rectangular band heater from Thermal Corporation, you will need to select a rectangular option from the mica band heaters section. Since rectangular band heaters are the same as mica band heaters, except for their shape, the purchasing details are basically the same as well. After you select your rectangular band heater option, next select your configurations. For more information on placing an order with Thermal Corporation, click here. 

Additional Options for Rectangular Band Heaters

• • Monel Sheath (NEW) – Used for caustic atmospheres. Available for most configurations.

• • 3 Phase or Dual Voltage – Available on all rectangular band heaters with post terminals or leads. Minimum size restrictions do apply. Contact us for more information.

• • Low Profile Terminals – Available on all rectangular band heaters with post terminals.

• • Ground Terminals or Ground Wire – Available for most rectangular band heater configurations. 

• • Non-Standard Location of Leads or Terminals – Can be placed at any reasonable location along the heater for applications where standard connections may not be accessible. Call us for more information.

• • Stainless Steel Sheath – For food processing applications, stainless steel sheath construction is available.
  • Holes or Notches – Any reasonable size and location of holes or notches is available for custom designed heaters. Call us for more information in determining feasibility.

• • Copper Elbow with Stainless Steel Hose – 3/8″ flexible hose soldered to elbow only available for configuration 415. When ordering, specify orientation of elbow to heater.

• • Copper Elbow with Stainless Steel Overbraid – 3/8″ stainless steel overbraid crimped to elbow available for configuration 415 only. When ordering, specify orientation of elbow to heater.

• • Bayonet Adapter Attached to Heater – Standard bayonet adapters are soldered to a bracket then attached to the heater above a 3/8″ diameter hole. When ordering, please specify adapter length.

• • Strain Relief Spring – Goes over a stainless steel overbraid (approximately 4″ coverage from where leads exit heater). Only Available for configuration 417.

• • 3 Phase and Dual Voltage T-Boxes – Available on almost all configurations with post terminals that are side-by-side.

• • European Connector – Two-pole cup European plugs available for almost all configurations. Minimum length and minimum width restrictions may apply. Contact us for more information.

• • Terminal Box – Available for most configurations with post terminals. Box is attached directly to the rectangular band heater. Call for more information.

 

Strip Heaters

Thermal Corporation’s strip heaters are manufactured with the most high quality materials available. Strip heaters are constructed by a resistance element being wound around mica, then insulated with mica on both sides of the element. A sheet of coated steel is then folded around the mica’s composite layers. Strip heaters are most commonly used to heat flat metal parts, such as platens and dies, by clamping one of the surfaces onto the metal part. They are also used for containers to heat liquid or solid containers. 

There are several configurations and options and accessories to choose from for your strip heater. 

Strip Heater Options:

• • Terminal Box – Available for configurations with post terminals.
  • Ground Terminal or Ground Wire – Can be added to configurations on custom items.
  • 3 Phase or Dual Voltage – Available for custom made heaters with leads or post terminals. Some restrictions may apply. Contact us for more details.

• • Non-Standard Location of Leads or Terminals – Leads or terminals may be added at any reasonable place along the strip heater where standard connections may not be accessible.

• • Stainless Steel Sheath – Commonly used for food process applications. Contact us for details.

• • Low Profile Terminals – Available on all heaters with post terminals. Contact us for details.

• • Holes or Notches – Available on custom heaters. Contact us for more details.

• • 90° Bend – Strip heaters can be custom bent for your application.

• • Copper Elbow with Stainless Steel Hose – 3/8″ flexible hose soldered to elbow available on heater configuration 014. Specify the orientation of the elbow to heater when ordering.

• • Copper Elbow with Stainless Steel Braid – Stainless steel braid attached to copper elbow available on Configuration 016. Specify the orientation of the elbow to heater when ordering.

• • European Connector – Cup-style European plug available on most strip heater configurations. Some restrictions may apply. Please contact us for more information.

 

If you are looking to purchase any of our band heaters, cartridge heaters, thermocouples, or RTD’s and need assistance with configurations or options, please contact us at (800) 633-2962 or send an email to our sales team at SALES@THERMALCORP.COM and someone will be happy to assist you. You can also request a free quote here.