---
title: The Hidden Costs of Choosing the Wrong Industrial Heater
description: Learn how to choose the right industrial heater to avoid hidden costs for the perfect heating solution that is efficient, safe, and sustainable.
image: https://marketing.backermarathon.com/hubfs/hidden-costs.jpg
---

[Skip to content](https://marketing.backermarathon.com/blog/the-hidden-costs-of-choosing-the-wrong-industrial-heater#main-content)

- [Blog](https://marketing.backermarathon.com/blog/)
- [Distributor Locator](https://www.backermarathon.com/locator/)
- [Online Retailers](https://www.backermarathon.com/online-resellers/)
- [About Us](https://www.backermarathon.com/about_us/)
- [Contact Us](https://www.backermarathon.com/contact/)

# Backer Marathon

[Backer Marathon](https://www.backermarathon.com/)

Toggle navigation Menu 

[Phone - 1-830-775-1417](tel:1-830-775-1417)

[Backer Marathon](https://www.backermarathon.com/)

- Call Us Today [1-830-775-1417](tel:1-830-775-1417)
- [Customer Portal](https://www.backermarathon.com/account/login.cfm)

- [![Home](https://www.backermarathon.com/_img/icon-home.png)](https://www.backermarathon.com/)
- [Heaters](https://www.backermarathon.com/products/heaters) [Heaters](https://www.backermarathon.com/products/heaters) 
    - | - [View all Heaters](https://www.backermarathon.com/products/heaters) - [Cartridge Heaters](https://www.backermarathon.com/products/cartridge-heaters/) - [Band Heaters](https://www.backermarathon.com/products/band-heaters/) - [Coil Heaters](https://www.backermarathon.com/products/coil-heaters/) - [Strip Heaters](https://www.backermarathon.com/products/strip-heaters/) - [Flexible Heaters](https://www.backermarathon.com/products/flexible-heaters/) - [Nozzle Heaters](https://www.backermarathon.com/products/nozzle-heaters/) - [Air Heaters](https://www.backermarathon.com/products/air-heaters/) - [Flexible Tubular Heaters](https://www.backermarathon.com/products/hotset-flexible/) - [Box Heaters](https://www.backermarathon.com/products/box-heaters/) | Cartridge Heaters Backer Marathon Heater's offers several cartridge heater styles with options for applications up to 1600°F. Choose from one of our thousands of in stock cartridge heater models or let our engineers design a custom heater for your application. Cartridge Heaters Brochure Download Band Heaters When heating is required around a nozzle or a pipe, a band heater is the optimal solution for your heating needs. Our current band products are separated in two types: Mica Band Heaters and Starflex Band Heaters. Each type offers different temperature tolerances as well as flexibility and construction options. Band Heaters Brochure Download Coil Heaters When highly focused heat is required and a very low profile is imperative, coil heaters are the best cost-effective option. Coil heaters may be used to concentrate the heat on specific segments or the coil may be spread to equalize the temperature across the object to be heated. Coil Heaters Brochure Download Strip Heaters Backer Marathon strip heaters are manufactured to your custom specifications. Mica Strip heaters offer a low profile option for applications of up to 1200°F. Ceramic Strip heaters offer a rugged construction for application of up to 1200°F. They are direct bolt in replacements for popular brands. Strip Heaters Brochure Download Flexible Heaters Backer Marathon flexible heaters provide outstanding performance in applications up to 450°F under a variety of operating conditions. Properly applied silicone rubber heater life routinely exceeds 10 years. Silicone rubber has a high dielectric strength, is flame retardant, and non-toxic. Design versatility permits special heat profiles allowing zones of higher or lower heat concentration and their flexible construction makes them easy to install on a variety of surfaces. Flexible Heaters Brochure Download Nozzle Heaters Backer Marathon Nozzle Heater Standard Features include; oxidation resistant metal sheath, protective sleeving where leads exit the heater, stainless steel clamping strap with barrel nuts and 6-32 screw, 10" High temperature leads with our without SS braid covering. 1" to 3" diameters and 1" to 6" widths are available. Backer Marathon Nozzle Heaters are also available in low profile wedgelock construction. Nozzle Heaters Brochure Download Air Heaters Backer Marathon air heaters feature an open coil of high temperature resistance wire electrically isolated in a stainless steel sheath. Because the air being heated passes directly over the resistance wire, maximum heat transfer efficiency is achieved. Backer Marathon brand air heaters are used for heat staking, plastic welding, laminating, drying, heat sealing, and any other operation where air needs to be heated up 1000° F. Air Heaters Brochure Download Hotset Flexible Tubular Heater Elements Backer Marathon is a distributor for HotSet flexible tubular heaters. HotSet flexible tubular heaters make the heating of complex platens, shapes, and machines possible. Simplify your machine design while reducing maintenance time and cost by using HotSet flexible heaters. Hotset Flexible Tubular Heater Elements Brochure Download Box Heaters Backer Marathon carries Mica Box Heaters. Box Heaters Brochure Download |
      | --- | --- |
- [Thermocouples](https://www.backermarathon.com/products/thermocouples) [Thermocouples](https://www.backermarathon.com/products/thermocouples) 
    - | - [View all Thermocouples](https://www.backermarathon.com/products/thermocouples) - [Mineral Insulated Thermocouples](https://www.backermarathon.com/products/mineral-insulated-thermocouples/) - [General Purpose Thermocouples](https://www.backermarathon.com/products/general-purpose-thermocouples/) - [Thermocouple Extensions & Accessories](https://www.backermarathon.com/products/thermocouple-extensions-accessories/) | Mineral Insulated Thermocouples Mineral Insulated Thermocouples are manufactured at Backer Marathon to address your higher temperature requirements. We stock hundreds of different models and offer quick turnaround, usually 48 hours or less, on custom designed and manufactured units. Mineral Insulated Thermocouples Brochure Download General Purpose Thermocouples Backer Marathon delivers low cost industrial thermocouples and RTDs available in a variety of configurations an types. Types J, K, T, 2 wire, and 3 wire RTDs are standard. Other types are available. We have a large inventory of stock thermocouples for immediate delivery. General Purpose Thermocouples Brochure Download Thermocouple Extensions & Accessories Backer Marathon is pleased to present thermocouple accessories and extensions as part of our line of premium temperature sensors. Backer Marathon has hundreds of different models in stock ready for immediate delivery. Thermocouple Extensions & Accessories Brochure Download |
      | --- | --- |
- [Applications](https://www.backermarathon.com/applications/heaters-for-oems-in-the-plastics-packaging-industry.cfm) [Applications](https://www.backermarathon.com/applications/heaters-for-oems-in-the-plastics-packaging-industry.cfm) 
    - - [Heaters for OEMs in the Plastics Packaging Industry](https://www.backermarathon.com/applications/heaters-for-oems-in-the-plastics-packaging-industry.cfm)
- [Support Center](https://www.backermarathon.com/contact) [Support Center](https://www.backermarathon.com/contact) 
    - - [Distributor Locator](https://www.backermarathon.com/locator/)
          - [Contact](https://www.backermarathon.com/contact/)
          - [Documents](https://www.backermarathon.com/documents/)
          - [Engineering Calculator](https://www.backermarathon.com/engineering-calculator/)
          - [Options](https://www.backermarathon.com/options/)
          - [Join Our Team](https://www.backermarathon.com/application/)
- Search
  
  Search

 Mar 12, 2025 12:27:45 PM

[Matt Brownson](https://marketing.backermarathon.com/blog/author/matt-brownson)

Share: [facebook-f icon](http://www.facebook.com/share.php?u=https://marketing.backermarathon.com/blog/the-hidden-costs-of-choosing-the-wrong-industrial-heater) [linkedin-in icon](http://www.linkedin.com/shareArticle?mini=true&url=https://marketing.backermarathon.com/blog/the-hidden-costs-of-choosing-the-wrong-industrial-heater) [Twitter icon](https://twitter.com/intent/tweet?url=https://marketing.backermarathon.com/blog/the-hidden-costs-of-choosing-the-wrong-industrial-heater) [pinterest-p icon](http://pinterest.com/pin/create/link/?url=https://marketing.backermarathon.com/blog/the-hidden-costs-of-choosing-the-wrong-industrial-heater) [envelope icon](mailto:?body=https://marketing.backermarathon.com/blog/the-hidden-costs-of-choosing-the-wrong-industrial-heater)

# **The Hidden Costs of Choosing the Wrong Industrial Heater**

 

**![hidden-costs](https://marketing.backermarathon.com/hs-fs/hubfs/hidden-costs.jpg?width=500&height=333&name=hidden-costs.jpg)**

## **How To Ensure Efficiency, Safety, and Long-term Savings**

When it comes to plastics and packaging, the [right industrial electric heater](https://www.backermarathon.com/applications/heaters-for-oems-in-the-plastics-packaging-industry.cfm) can make all the difference. It keeps things running smoothly, saves money, and helps maintain product quality. But choosing the wrong one? That can lead to all sorts of hidden costs, from higher energy bills to unexpected downtime. Let’s take a closer look at what can go wrong—and how to get it right from the start.

 

## **1. Increased Energy Costs**

One of the most immediate and substantial hidden costs of using the wrong heater is excessive energy consumption. Heaters that are inefficient struggle to maintain required temperatures, leading to longer run times and higher electricity or fuel bills.

**What You Can Do:**

- Choose a heater with the [right wattage](https://marketing.backermarathon.com/blog/watt-density-explained?hsLang=en-us) and efficiency rating for your specific plastics or packaging application.
- Implement smart heating controls that regulate temperature based on real-time demand.

## **2. Maintenance and Repair Expenses**

The wrong heater can also lead to frequent breakdowns and increased maintenance costs. If a heater is not designed to [handle the operational load](https://marketing.backermarathon.com/blog/voltage-spikes-their-impacts-and-how-to-mitigate-them?hsLang=en-us) or environmental conditions in plastics and packaging facilities, components wear out faster, requiring regular repairs or replacements.

**What You Can Do:**

- Work with heating experts to select a unit designed for your industry’s specific needs and working conditions.
- Schedule regular maintenance and inspections to catch issues early and extend the heater’s lifespan.
- Invest in high-quality industrial heaters with durable materials and robust construction.
- Look beyond the heaters as well to your sensors and power control systems.

 

## **3. Reduced Equipment Lifespan**

An industrial heater that is mismatched to the job at hand can shorten the lifespan of surrounding equipment. Poor heat distribution can lead to thermal stress on machinery used in extrusion, molding, and other packaging processes, causing premature wear and tear.

**What You Can Do:**

- Opt for heaters with uniform heat distribution and temperature regulation to avoid localized overheating.
- Ensure proper installation and placement to minimize unnecessary strain on processing equipment.
- Consider heat-resistant coatings and insulation to protect surrounding equipment from excessive temperatures.

 

## **4. Production Inefficiencies and Downtime**

Inconsistent or inadequate heating can disrupt plastics and packaging processes, leading to production delays, inconsistent product quality, and even equipment shutdowns. These inefficiencies can translate into substantial revenue loss over time.

**What You Can Do:**

- Conduct a comprehensive heating-needs analysis to determine the most effective heating solution for your processes.
- Train personnel on best practices for heater operation and troubleshooting to avoid unnecessary downtime.

 

## **5. Safety Hazards and Compliance Issues**

Industrial heaters that do not meet safety standards or are improperly installed can pose serious risks, including fire hazards, electrical failures, and workplace injuries. Additionally, failing to comply with industry regulations can result in fines, legal liabilities, and damage to your company’s reputation.

**What You Can Do:**

- Choose heaters that meet industry safety certifications and compliance standards for plastics and packaging.
- Conduct regular safety audits and inspections to identify and address potential risks.
- Ensure proper ventilation, wiring, and protective enclosures for heater installations.

 

## **6. Environmental Impact and Sustainability Concerns**

Inefficient heating systems contribute to excessive energy consumption and carbon emissions, which are detrimental to both operational costs and environmental responsibility. Many plastics and packaging companies today are under pressure to reduce their carbon footprint, and inefficient heaters can make sustainability goals harder to achieve.

**What You Can Do:**

- Invest in energy-efficient and eco-friendly industrial heaters, such as those powered by renewable energy sources or utilizing heat recovery systems.
- Implement insulation and waste heat recovery to minimize energy loss and improve overall efficiency.
- Monitor energy consumption and adopt greener practices to align with sustainability initiatives.

 

## **7. Hidden Labor Costs**

If employees frequently have to adjust, repair, or troubleshoot an inefficient industrial heater, this can lead to wasted labor hours that could be better spent on core operational tasks.

**What You Can Do:**

- Select heaters with user-friendly controls and automated operation to reduce manual intervention.
- Train staff on how to optimize heater performance and recognize early signs of inefficiency.

 

**Making the Right Choice from the Start**

Selecting the right industrial heater from the outset can save your business significant money, time, and effort in the long run. Here are some key considerations when choosing a heating solution for plastics and packaging operations:

- **Understand your heating requirements:** Consider factors such as the type of plastic being processed, extrusion temperatures, and packaging line needs.
- **Evaluate energy efficiency ratings:** Look for heaters with high energy efficiency ratings to lower operational costs.
- **Consider future scalability:** Ensure that your heating solution can accommodate future expansion or increased production needs.
- **Work with reputable suppliers:** Partnering with [experienced industrial heating providers](https://marketing.backermarathon.com/blog/we-know-cartridge-heaters?hsLang=en-us) can help you make an informed decision based on expert recommendations.

 

Choosing the wrong industrial heater can lead to all sorts of hidden expenses, from high energy bills and frequent maintenance to unexpected downtime, safety risks, and environmental impact. But with a little planning, you can find the perfect heating solution that keeps your business running efficiently, safely, and sustainably.

Need help finding the right industrial heater for your plastics and packaging operations? [Reach out to our experts for a consultation today](https://www.backermarathon.com/contact/)—we’ll help you make the best choice from the start!

 

**Why Backer Marathon**

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 since 1996. We design, manufacture, and stock industrial-grade heating elements and temperature sensors. Engineers have live, on-demand access via phone to our trained technical experts who have been pioneers in this sector for decades.

How can Backer Marathon’s experts help you today? Nosotros hablamos español. [**Contact us today**](https://www.backermarathon.com/contact/)to discuss your next project.

[Industrial heaters](https://marketing.backermarathon.com/blog/tag/industrial-heaters), [heating solutions](https://marketing.backermarathon.com/blog/tag/heating-solutions), [savings](https://marketing.backermarathon.com/blog/tag/savings)

## Related posts

[![](https://marketing.backermarathon.com/hs-fs/hubfs/ceramic-band-heater.jpg?height=200&name=ceramic-band-heater.jpg)](https://marketing.backermarathon.com/blog/ceramic-band-heaters-for-cylinder-applications?hsLang=en-us)

[Industrial heaters](https://marketing.backermarathon.com/blog/tag/industrial-heaters), [ceramic band heater](https://marketing.backermarathon.com/blog/tag/ceramic-band-heater), [cylinder applications](https://marketing.backermarathon.com/blog/tag/cylinder-applications)

## [Ceramic Band Heaters for Cylinder Applications](https://marketing.backermarathon.com/blog/ceramic-band-heaters-for-cylinder-applications?hsLang=en-us)

[Matt Brownson](https://marketing.backermarathon.com/blog/author/matt-brownson) 

 Feb 5, 2025 1:59:02 PM

Ceramic Band Heaters for Cylinder Applications The Heat Behind the Precision When it comes to...

[Read more](https://marketing.backermarathon.com/blog/ceramic-band-heaters-for-cylinder-applications?hsLang=en-us)

[![](https://marketing.backermarathon.com/hs-fs/hubfs/density-analogy.jpg?height=200&name=density-analogy.jpg)](https://marketing.backermarathon.com/blog/watt-density-explained?hsLang=en-us)

[watt density](https://marketing.backermarathon.com/blog/tag/watt-density), [Industrial heaters](https://marketing.backermarathon.com/blog/tag/industrial-heaters)

## [Watt Density Explained](https://marketing.backermarathon.com/blog/watt-density-explained?hsLang=en-us)

[Matt Brownson](https://marketing.backermarathon.com/blog/author/matt-brownson) 

 Oct 7, 2024 12:03:49 PM

Watt Density Explained A Complete Guide to Its Importance in a Variety of Industries Think about a...

[Read more](https://marketing.backermarathon.com/blog/watt-density-explained?hsLang=en-us)

[![](https://marketing.backermarathon.com/hs-fs/hubfs/voltage%20spikes.jpg?height=200&name=voltage%20spikes.jpg)](https://marketing.backermarathon.com/blog/voltage-spikes-their-impacts-and-how-to-mitigate-them?hsLang=en-us)

[voltage spikes](https://marketing.backermarathon.com/blog/tag/voltage-spikes), [electric heaters](https://marketing.backermarathon.com/blog/tag/electric-heaters), [mitigations](https://marketing.backermarathon.com/blog/tag/mitigations)

## [Voltage Spikes: Their Impacts and How to Mitigate Them](https://marketing.backermarathon.com/blog/voltage-spikes-their-impacts-and-how-to-mitigate-them?hsLang=en-us)

[Matt Brownson](https://marketing.backermarathon.com/blog/author/matt-brownson) 

 Nov 19, 2024 1:26:55 PM

Voltage Spikes: Their Impacts and How to Mitigate Them Voltage spikes that exceed an electrical...

[Read more](https://marketing.backermarathon.com/blog/voltage-spikes-their-impacts-and-how-to-mitigate-them?hsLang=en-us)

#### Products

- [Cartridge Heaters](https://www.backermarathon.com/products/cartridge-heaters/)
- [Band Heaters](https://www.backermarathon.com/products/band-heaters/)
- [Coil Heaters](https://www.backermarathon.com/products/coil-heaters/)
- [Strip Heaters](https://www.backermarathon.com/products/strip-heaters/)

- [Flexible Heaters](https://www.backermarathon.com/products/flexible-heaters/)
- [Nozzle Heaters](https://www.backermarathon.com/products/nozzle-heaters/)
- [Air Heaters](https://www.backermarathon.com/products/air-heaters/)
- [Flexible Tubular Heaters](https://www.backermarathon.com/products/hotset-flexible/)
- [Box Heaters](https://www.backermarathon.com/products/box-heaters/)

#### Support / Site Tools

- [Distributor Locator](https://www.backermarathon.com/locator/)
- [Contact](https://www.backermarathon.com/contact/)
- [Documents](https://www.backermarathon.com/documents/)
- [Engineering Calculator](https://www.backermarathon.com/engineering-calculator/)

- [Options](https://www.backermarathon.com/options/)
- [Join Our Team](https://www.backermarathon.com/application/)
- [Careers](https://www.backermarathon.com/careers)

![Backer Marathon](https://www.backermarathon.com/_img/footer-logo.png)

---

© 2024 Backer Marathon Inc. All Rights Reserved.

![Inc. 5000](https://www.backermarathon.com/_img/logo-inc-5000.png)

Backer Marathon is a US-based heating elements and sensor manufacturer. We specialize in Cartridge Heaters, Band Heaters, Ceramic Heaters, Mica Heaters, Air Heaters, Tubular Heaters, and Thermocouples. We manufacture for OEM as well as stock replacements for popular brands.

```json
{
  "@context" : "https://schema.org",
  "@type" : "BlogPosting",
  "author" : {
    "@type" : "Person",
    "name" : "Matt Brownson",
    "url" : "https://marketing.backermarathon.com/blog/author/matt-brownson"
  },
  "dateModified" : "2025-03-12T16:27:45.969Z",
  "datePublished" : "2025-03-12T16:27:45.000Z",
  "headline" : "The Hidden Costs of Choosing the Wrong Industrial Heater",
  "image" : [ "https://marketing.backermarathon.com/hubfs/hidden-costs.jpg" ],
  "mainEntityOfPage" : {
    "@id" : "https://marketing.backermarathon.com/blog/the-hidden-costs-of-choosing-the-wrong-industrial-heater",
    "@type" : "WebPage"
  },
  "publisher" : {
    "@type" : "Organization",
    "logo" : {
      "@type" : "ImageObject",
      "url" : "https://marketing.backermarathon.com/hubfs/bm-logo-400x100.jpg"
    },
    "name" : "Backer Marathon Inc."
  }
}
```