Selecting the Right Process Heater When Working with Plastics and Rubber

Temperature Control Considerations with Plastic Processing

Processing plastics and rubber involves several important factors that impact the quality, efficiency, and cost effectiveness of the manufacturing process. Some of these key factors are:

·      Materials

·      Pressure Control

·      Temperature Control

·      Mold and Tooling Design

Let’s explore temperature control and its impact on your system and process. At its most basic level, the standard temperature control system is comprised of a process heater, a temperature sensor, a temperature controller, and a relay/switch. Selecting the correct process heater style is the key to successful processing over the long term.

The table below ranks various heaters by key features the OEM processor will want to consider, such as:

·      Durability: How “rugged” is this heater as needed for the conditions/environment of use?

·      Efficiency: What’s the highest return for energy invested?

·      Temperature Rating: Are you running a high-temperature process?

·      Availability: Are these items in stock, or available for expedition in case of unplanned events?

High Temperature: What Are My Best Higher-Temperature Product Options?

Ceramic Band Heaters (cylinder installations) – 1400dF

View this and other specifications here.

Common Applications: injection molding barrels, blow molding barrels/die head

Ceramic band heaters are preferred for high-temperature options in cylinder installations for injection molding barrels, blow molding barrels, and die heads due to their specific features and advantages tailored to these applications.

High Temperature Resistance: Ceramic band heaters are designed to withstand high temperatures commonly encountered in injection molding, blow molding, and die head processes. They are constructed using high-quality ceramic materials that offer excellent heat resistance, ensuring reliable performance even in extreme operating conditions.

Uniform Heating: These ceramic band heaters provide uniform and efficient heating across the entire circumference of the cylinder, ensuring consistent temperature distribution throughout the barrel or die head. This uniform heating profile helps optimize material flow, viscosity, and mold filling, resulting in improved product quality and dimensional accuracy.

Fast Heat-Up Time: Ceramic band heaters have a rapid heat-up time, allowing them to reach operating temperatures quickly and efficiently. This fast heat-up time reduces startup times and minimizes production delays, enhancing overall process efficiency and productivity.

Precise Temperature Control: Ceramic band heaters offer precise temperature control, enabling operators to maintain the desired temperature setpoints for injection molding barrels, blow molding barrels, and die heads. This precise control ensures optimal processing conditions and helps prevent material degradation, overheating, or underheating issues during production.

Easy Installation and Maintenance: Ceramic band heaters are designed for easy installation and maintenance on cylinder installations such as injection molding barrels, blow molding barrels, and die heads. They can be quickly mounted and secured around the circumference of the cylinder using clamping mechanisms or other fastening methods. Routine maintenance tasks, such as cleaning or inspection, can also be performed with ease, minimizing downtime and maximizing equipment uptime.

Versatility: Ceramic band heaters are versatile and adaptable to different cylinder sizes and configurations commonly found in injection molding, blow molding, and die head applications. They are available in various diameters, lengths, wattages, and voltage ratings to accommodate specific heating requirements and application needs.

The use of certain ceramic band heaters for high-temperature options in cylinder installations for injection molding barrels, blow molding barrels, and die heads provides reliable, uniform, and precise heating solutions essential for optimizing production processes, improving product quality, and enhancing operational efficiency in industrial manufacturing settings.

Ceramic Strip Heaters (flat installations and channels) – 1200dF

View this and other specifications here.

Common Applications: extrusion die heads, platen inserts (channels)

Ceramic strip heaters are commonly used in flat installation and channel applications for extrusion die heads and platen inserts (channels) due to their specific features and advantages tailored to these requirements.

Space Efficiency: Ceramic strip heaters are designed to be thin and flat, making them ideal for installations in confined spaces such as channels and narrow slots. Their compact profile allows for efficient use of space within extrusion die heads and platen insert channels without obstructing the flow of materials or interfering with the operation of machinery.

Uniform Heating: These heaters provide uniform heat distribution across their entire surface area, ensuring consistent temperature profiles along the length of the channel or die head. Uniform heating is critical in extrusion processes to maintain precise control over material flow and viscosity, resulting in consistent product quality and dimensional accuracy.

High Temperature Capability: Ceramic strip heaters are capable of reaching and maintaining high temperatures required for extrusion processes. They are constructed using heat-resistant ceramic materials that can withstand elevated temperatures without deformation or degradation, ensuring reliable performance under demanding operating conditions.

Precise Temperature Control: Ceramic strip heaters offer precise temperature control, allowing operators to adjust heating levels according to specific extrusion requirements. This precise control enables fine-tuning of the extrusion process parameters to achieve desired material properties, surface finishes, and dimensional tolerances.

Fast Response Time: These heaters have a rapid heat-up and cool-down time, facilitating quick adjustments to temperature changes during start-up, shut-down, or process variations. The fast response time of ceramic strip heaters enhances process efficiency and flexibility, minimizing downtime and optimizing production throughput.

Easy Installation and Maintenance: Ceramic strip heaters are easy to install and maintain in flat installation and channel applications. They can be securely mounted using various methods such as clamps, bolts, or adhesive tape, and routine maintenance tasks such as cleaning or inspection can be performed quickly and conveniently, minimizing downtime and maximizing productivity.

OEMs prefer ceramic strip heaters for flat installation and channel applications in extrusion die heads and platen insert channels due to their space efficiency, uniform heating, high temperature capability, precise temperature control, fast response time, durability, longevity, and ease of installation and maintenance. These heaters play a crucial role in optimizing extrusion processes and ensuring consistent product quality in various industrial applications.

Cartridge Heaters (insertion-style application) – 1600dF

·      Swaged (HotRods): compacted, high-watt density

·      Non-Swaged: not compacted, low-watt density, cost effective, good for tight size tolerances with removal of swaging process

·      Square: swaged/compacted, high-watt density, ideally for fitting into milled slots where insertion would be difficult

Common Applications: extrusion barrels, pelletizer dies, strand die heads, profile dies, injection molds               

Swaged, non-swaged, and square cartridge heaters with insertion-style applications are commonly used for their higher temperature features in extrusion barrels, pelletizer dies, strand die heads, profile dies, and injection molds due to several key advantages tailored to these applications.

High-Temperature Capability: These types of cartridge heaters are specifically designed to withstand and operate at elevated temperatures commonly encountered in extrusion and injection molding processes. They are constructed using high-quality materials such as stainless steel or Incoloy®, which exhibit excellent heat resistance and can maintain stable temperatures even in demanding industrial environments.

Efficient Heat Transfer: Cartridge heaters feature a compact cylindrical design that allows for efficient heat transfer to the surrounding material or mold. Their insertion-style application ensures direct contact with the barrel, die head, or mold cavity, enabling rapid and uniform heating throughout the process. This efficient heat transfer minimizes energy consumption and enhances process efficiency, resulting in reduced cycle times and increased productivity.

Precise Temperature Control: Swaged, non-swaged, and square cartridge heaters offer precise temperature control, allowing operators to maintain consistent temperature profiles within extrusion barrels, pelletizer dies, strand die heads, profile dies, and injection molds. This precise control is essential for achieving optimal material flow, viscosity, and dimensional accuracy, ensuring uniform product quality and performance.

Versatility and Compatibility: These cartridge heaters come in various configurations, including swaged, non-swaged, and square shapes, to accommodate different installation requirements and space constraints. Their insertion-style design makes them compatible with a wide range of industrial equipment, such as extruders, pelletizers, die heads, and injection molding machines, providing versatility and flexibility in application.

Fast Response Time: Cartridge heaters have a rapid heat-up and cool-down time, allowing for quick adjustments to temperature changes during start-up, shut-down, or process variations. Their efficient heating elements and direct contact with the heating medium facilitate fast response times, minimizing downtime and optimizing production throughput in extrusion and injection molding operations.

Durability and Longevity: These cartridge heaters are engineered for durability and longevity, capable of withstanding the rigors of continuous operation and frequent heating cycles. They are resistant to mechanical stress, thermal shock, and corrosion, ensuring reliable performance over an extended service life with minimal maintenance requirements.

Easy Installation and Maintenance: Swaged, non-swaged, and square cartridge heaters are designed for easy installation and maintenance in extrusion barrels, pelletizer dies, strand die heads, profile dies, and injection molds. Their insertion-style application allows for simple mounting and removal, while routine maintenance tasks such as cleaning or inspection can be performed quickly and conveniently, minimizing downtime and maximizing equipment uptime.

When OEMs need higher temperature features in extrusion and injection molding applications with swaged, non-swaged, and square cartridge heaters for insertion-style applications, they are looking to attain:

·      High-temperature capability

·      Efficient heat transfer

·      Precise temperature control

·      Versatility

·      Compatibility

·      Fast response time

·      Durability

·      Longevity

·      Ease of installation and maintenance

These cartridge heaters also play a crucial role in optimizing process performance, enhancing product quality, and increasing operational efficiency in various industrial settings.

Durability: What Are My Best Durability Product Options?

Starflex Band Heater (round installations)

·      Heavy duty and enclosed extruded aluminum and high-temperature insulated tubular style heating elements

·      Bonus feature: can order as cooling only or heating/cooling combination

Common Applications: extrusion barrels, injection barrels, blow molding barrels, co-extrusion barrels

Starflex band heaters are manufactured by hydraulically pressing a high temperature heating element into a precision-grooved aluminum channel. The heaters are clamped in place with low-expansion stainless-steel straps for intimate contact with the part. The aluminum channel offers low mass and high thermal conductivity for fast heat up. These same characteristics provide excellent cool down properties as well, which is why Starflex bands are also available with water cooling, both as a cool-only band and a heat/cool band. They are preferred for their durability features in round installations for extrusion barrels, injection barrels, blow molding barrels, and co-extrusion barrel applications due to several key advantages tailored to these specific industrial processes.

High Temperature Resistance: Starflex band heaters are designed to withstand high temperatures commonly encountered in extrusion, injection molding, and blow molding processes. They are constructed using high-quality materials such as stainless steel or nickel-chromium alloy, ensuring reliable performance even in extreme operating conditions.

Durable Construction: These band heaters feature a robust and rugged construction that is highly resistant to mechanical stress, thermal cycling, and chemical exposure. They are built to withstand the rigors of industrial environments, including the intense heat and pressure present in extrusion and molding applications, ensuring OEMs of long-term reliability and durability.

Uniform Heating: Starflex band heaters provide uniform and efficient heating around the circumference of the barrel, ensuring consistent temperature distribution throughout the entire barrel surface. This uniform heating profile helps optimize material flow, viscosity, and mold filling, resulting in improved product quality and dimensional accuracy.

Excellent Heat Transfer: The innovative design of Starflex band heaters maximizes heat transfer efficiency, allowing for rapid and uniform heating of the barrel. This efficient heat transfer capability minimizes energy consumption and reduces heating times, resulting in increased production throughput and lower operating costs.

Easy Installation and Maintenance: Starflex band heaters are designed for easy installation and maintenance on round installations such as extrusion barrels, injection barrels, blow molding barrels, and co-extrusion barrels. They can be quickly mounted and secured around the circumference of the barrel using clamping mechanisms or other fastening methods. Routine maintenance tasks, such as cleaning or inspection, can also be performed with ease, minimizing downtime and maximizing equipment uptime.

Versatility: Starflex band heaters are versatile and adaptable to different barrel sizes and configurations commonly found in extrusion and molding applications. They are available in various diameters, lengths, wattages, and voltage ratings to accommodate specific heating requirements and application needs, making them suitable for a wide range of industrial processes.

Starflex band heaters are used for their durability features in round installations for extrusion barrels, injection barrels, blow molding barrels, and co-extrusion barrel applications because they provide reliable and efficient heating solutions essential for optimizing production processes, improving product quality, and enhancing operational efficiency in industrial OEM production environments.

Starflex Strip Heater (flat/surface installations)

·      Heavy duty and enclosed extruded aluminum and high-temperature insulated tubular style heating elements

·      Even heating distribution with aluminum body

Common Applications: mold heating, extrusion dies, blow molding preform dies

Starflex strip heaters offer rugged durability and temperature uniformity not found in mica strip heaters. The resistance wire is encased in a tubular heating element, offering protection from harsh environments. The aluminum body provides even temperature across the whole surface, which translate to no hot spots! They are chosen for their durability features in flat or surface installations for mold heating, extrusion die, and blow molding preform die applications due to their specific advantages tailored to these industrial processes.

High Temperature Capability: Starflex strip heaters are engineered to withstand high temperatures required for mold heating, extrusion die, and blow molding preform die applications. Constructed from high-quality materials such as stainless steel or nickel-chromium alloy, these heaters can endure the extreme heat encountered during heating processes without compromising performance.

Robust Construction: These strip heaters feature a robust and rugged design that can withstand mechanical stress, thermal cycling, and exposure to harsh operating conditions. Their durable construction ensures reliable and consistent performance over extended periods, even in demanding industrial environments.

Uniform Heating: The uniform heating provided by Starflex strip heaters radiates across the entire surface of molds, extrusion dies, or blow molding preform dies. This uniform heating profile helps maintain precise and consistent temperatures throughout the heating process, ensuring optimal material flow, viscosity, and mold filling for high-quality end products.

Efficient Heat Transfer: The design of Starflex strip heaters maximizes heat transfer efficiency, allowing for rapid and efficient heating of molds, extrusion dies, or blow molding preform dies. This efficient heat transfer capability reduces heating times, minimizes energy consumption, and improves overall production efficiency.

Easy Installation and Maintenance: These specialized heaters are designed for easy installation and maintenance in flat or surface installations. Starflex strip heaters can be quickly mounted onto molds, extrusion dies, or blow molding preform dies using adhesive backing or other fastening methods. Additionally, routine maintenance tasks, such as cleaning or inspection, can be performed with minimal effort, reducing downtime and maximizing productivity.

Versatility: Starflex strip heaters are versatile and adaptable to various mold sizes, shapes, and configurations commonly used in mold heating, extrusion die, and blow molding preform die applications. They are available in different lengths, widths, wattages, and voltage ratings to accommodate specific heating requirements and application needs, making them suitable for a wide range of industrial processes.

OEMs require reliable and efficient heating solutions that are essential for optimizing production processes, improving product quality, and enhancing operational efficiency in industrial manufacturing environments, which is why Starflex strip heaters are the preferred choice for their durability features in flat or surface installations for mold heating, extrusion die, and blow molding preform die applications.

Other Design Considerations

Ease of Installation/Flexibility: Often companies can’t take an entire barrel or die apart to remove a heater. Certain heaters lend themselves to ease of use in this area.

·      Ceramic Band Heaters: Since they are made with a series of ceramic tiles, the heaters have a high level of flexibility to completely open and remove with no disruption to the rest of the process.

·      Mica Band Heaters: Normally relatively rigid, but the outer sheath material can be “notched” to make the heater fully expandable. They can also be made as a two-piece heater.

Custom Voltages

A key requirement of all process heaters is to match the heater voltage rating with the supply voltage. If a higher voltage is supplied than the heater is cable of, the effects are complete failure and safety issues. Backer Marathon uses multiple checkpoints in the manufacturing process to ensure and confirm voltage is accurate prior to ship out.

·      Dual Voltage: At times, OEMs want to select a heater that will accommodate a wider range of plant supply voltages rather than ordering, stocking, and specifying multiple voltage versions of otherwise same heaters. Backer Marathon can build heaters with two different voltages that will allow a processor to wire the heaters and use under 240-volt and 480-volt supplies, for example. The requestor will need to let the sales engineer know this requirement on the front end of the RFQ process. 

·      Unique Voltages: Most are very familiar with the U.S. standards of 120 volt, 240 volt, and 480 volt, but at times (particularly in older facilities), a facility will experience voltage spikes that exceed these traditional voltage tolerances. If there are situations where a processor is seeing “mystery” failures, you’ll want to verify the voltage is stable and under the tolerance of the heater. If you see peaks that exceed the rated voltage, please contact your Backer Marathon sales engineer and we can design a heater with the custom voltage. 

Internal Thermocouples

At times, there is not a good option to add a thermocouple or temperature sensor to a process. Usually this is a tight clearance application or one lacking the space to introduce the mechanical size of the thermocouple. In these instances, Backer Marathon offers an internal thermocouple. These are currently available in Type J and Type K, but if you have an internal sensor need beyond this, contact your Backer Marathon sales engineer.

Helping OEMs Heat Up 

Backer Marathon is the industry leader in production speed and reliable, quality heaters for plastics and packaging, serving OEMs with durable, customized solutions for unique heating needs. Backer Marathon designs, manufactures, and stocks industrial-grade heating elements and temperature sensors.

Engineers have direct access to our trained technical experts who have been pioneers in this sector for decades. Our vast array of heaters serves diverse industries and applications—from food and beverage packaging to industrial platens used in compression molders.

We believe in hard work, creative engineering, and excellent customer service. Whether you need one piece or one thousand, Backer Marathon is committed to providing you with exactly what you need when you need it. As we innovate and lead the industry with unparalleled engineering and customer service, we look forward to helping you continue to grow with us. Let’s talk about your next project. Contact us now or call us today at 1 (830) 775-1417. We’re excited to collaborate with you.