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Band Heater Manufacturers
One-stop solution for band heaters
manufactures high-performance band heaters designed to heat cylindrical surfaces such as extruder barrels, injection molding barrels and nozzles, die heads, and drums. We offer a full portfolio— Mica, Ceramic, Cast-In (Heat & Cool), Mineral-Insulated (MI), Nozzle, and Formed Tubular—covering applications from general-purpose to high watt density and harsh environments.
Product Families
Mica Band Heaters (General Purpose)
Cost-effective and versatile. Ideal for clean environments and moderate temperatures. Typical max temperature up to ~900°F (480°C). Quick heat-up, low profile, many clamping styles.
- Typical watt density: up to [W/in² value, e.g., 35]
- Common sheath: Stainless steel
- Options: Leads, screw terminals, European plugs, integral insulation
Ceramic Band Heaters (Higher Temperature & Efficiency)
Ceramic-insulated construction for higher temperature capability and improved heat retention. Good for barrel heating where thermal efficiency matters.
- Typical max temperature: up to ~1200°F (650°C)
- Typical watt density: up to [45–60 W/in²] depending on fit
- Options: Built-in insulation, protective shrouds, air or water-cooling jackets
Cast-In Band Heaters (Heat & Cool Assemblies)
Aluminum or bronze cast bodies with embedded tubular heaters. Excellent thermal uniformity and mechanical strength; can integrate air/water cooling channels for tight temperature control on extrusion lines.
- Max temperature: up to [700–900°F / 370–480°C] (material dependent)
- Integrated cooling: air fins, air jackets, or water channels
- Custom bore/OD/width, split designs, RTD/TC sensors
Mineral-Insulated (MI) / High Watt Density Bands
Compact, high watt density designs with excellent heat transfer—suited for demanding, space-constrained barrel zones and contaminant-prone environments when properly sealed.
- Typical watt density: up to [60–80+ W/in²] with proper fit
- Fast response; rugged terminations
- Sealed options for oily/dirty environments
Nozzle Heaters
Slim, uniform-wrap heaters for injection nozzles and die necks. Form-fit designs minimize heat loss and improve temperature stability at critical flow points.
- Tight ID tolerances; partial or full coverage
- Grounded/ungrounded thermocouple options
- Low mass for fast startup, optional insulation jackets
Formed Tubular / Custom Rings
Tubular elements configured into rings or partial circles for oversize diameters, special geometries, or unusual mounting envelopes.
Common Applications
Injection molding barrels & nozzles
Extrusion barrels and die heads
Blow molding, film & sheet lines
Hot runner manifolds (select nozzle styles)
Drum & pail heating (with proper insulation)
Why Choose Elekheat Band Heaters
Broad temperature range
Engineered watt density
Robust construction
Fast turnaround
Application support
Quick Selection Guide
| Type | Typical Max Temp | Typical Watt Density | Best For | Notes |
|---|---|---|---|---|
| Mica | ~900°F / 480°C | Up to ~35 W/in² | General purpose, clean environments | Lowest cost; many clamp/lead options |
| Ceramic | ~1200°F / 650°C | ~45–60 W/in² | Higher temps, better efficiency | Add insulation/shroud for energy savings |
| Cast-In | ~700–900°F / 370–480°C | Zone-engineered | Uniformity, ruggedness, heat & cool | Air/water cooling integration available |
| MI (Mineral-Insulated) | ~1200°F / 650°C | ~60–80+ W/in² | High watt density, compact spaces | Requires excellent barrel fit |
| Nozzle | ~1000–1200°F / 540–650°C | Application specific | Nozzles, die necks | Thermocouple options; tight tolerances |
Sizing & Watt Density Tips
Fit is Critical
Aim for a snug fit on clean, round barrels. Gaps reduce heat transfer and shorten life.
Watt Density
Choose the lowest W/in² that achieves your heat-up time and holds setpoint under load.
Zoning
Split large barrels into multiple zones for better control and maintenance.
Insulation
Add insulation or shrouds to cut losses, especially on ceramic or cast-in designs.
Environment
Use sealed or shrouded options in oily, dusty, or corrosive atmospheres.
Diameter range: [e.g., 25 mm – 500 mm] (custom larger sizes on request)
Widths: [e.g., 25 / 32 / 38 / 50 mm] and custom
Voltage: [120 / 230 / 240 / 380 / 480 VAC], single or three-phase (by model)
Wattage: Sized per zone and surface area; consult Engineering for W/in² guidance
Electrical tolerance: ±[10%] typical unless specified
Resistance tolerance: ±[10%] typical unless specified
Thermocouple: Type J/K, grounded/ungrounded (select models)
Lead exits & terminations: Leads, lugs, post terminals, plugs, strain reliefs
Certifications: [ISO 9001], [RoHS], [REACH]
Have a Question?
At ELEKHEAT, we’re here to provide the answers you need. Whether you’re looking for product information, technical specifications, or need assistance with maintenance, our team of experts is ready to help. Don’t hesitate to reach out—we’re committed to ensuring you get the support you need for the best heating solutions.
What is a Band Heater?
A band heater is an electric heating device designed to clamp around cylindrical surfaces, such as extruder and injection molding barrels. By transferring heat evenly through close contact, it maintains stable process temperatures. Common constructions include mica, ceramic, cast-in, and mineral-insulated designs, chosen by temperature, watt density, and environment.
The Essentials at a Glance
| Spec | Why it matters | Typical ranges / notes |
|---|---|---|
| Diameter (ID) & width | Must match the heated surface; width drives contact area | ID from 10–1,000+ mm (⅜″–40+″); widths 12–100 mm (½″–4″) |
| Voltage | Matches supply & controls | 120/230–240/400–480 V most common |
| Wattage | Determines heat rate | 50 W (tiny nozzles) → 3+ kW (large zones) |
| Watt density | Power per area; too high shortens life | Mica: 5–20 W/in² (0.8–3.1 W/cm²) • Ceramic: 10–45 W/in² (1.6–7.0 W/cm²) • Mineral-insulated: 15–60 W/in² (2.3–9.3 W/cm²) |
| Max sheath temp | Material limit | Mica ≈ up to 480 °C (900 °F) • Ceramic ≈ up to 650 °C (1,200 °F) • Mineral/MI ≈ up to 760 °C (1,400 °F) |
| Thermocouple | Feedback for control | Type J or K most common; place in each zone |
| Clamping & split | Affects heat transfer/maintenance | One-piece, two-piece, or expandable; toggle latches for quick change |
Types (and when to choose them)
Mica band (thin, fast heat, cost-effective)
Best for plastics up to ~350 °C setpoints, light to moderate duty, good contact surfaces.Ceramic band (insulated, efficient at mid-high temps)
Choose for 350–500 °C surfaces, when you want lower skin temperature and better energy efficiency.Mineral-insulated (MI) / high-performance
For tight spaces and high heat flux; fastest response, highest watt density. Use when cycles are rapid or loads heavy.Cast aluminum/brass bands
Excellent heat spreading and durability; common on extruder barrels in harsh environments.Drum band heaters (steel or silicone-insulated)
Designed to warm 5–220 L containers (e.g., 20–55 gal) for oils/adhesives/food syrups; pair with lid heaters for uniformity.
FAQ (copy anywhere on page)
Band Heaters — Frequently Asked Questions
A: Use the lowest W/in² that achieves required heat-up and holds setpoint. Ensure excellent barrel contact; poor fit forces higher W/in² and shortens life.
A: Ceramic bands handle higher temperatures and retain heat better, improving efficiency. Mica bands are more economical for moderate temperatures in clean environments.
A: When you need rugged construction, very uniform heat, or integrated cooling (air/water) for tight temperature control—common on extrusion lines.
A: Yes, when you want faster heat-up and energy savings, or when ambient conditions cause heat loss. Ceramic bands especially benefit from shrouds.
A: Poor fit, contamination (oil/plastic), over-tightening/under-tightening, or excessive watt density. Clean surfaces and correct torque extend life.
A: Yes. We offer custom diameters, widths, voltages, wattages, clamping, lead exits, and sensor options with short lead times.
