The Importance of Soft Starting Controls to Bake Out Cartridge Heaters

Soft starting and baking out electrical cartridge heaters are important primarily to remove moisture that may have accumulated inside the heater body during storage, handling, or previous use.  

Importance of Soft Start and Bake Out:

1. Moisture Removal: 

* Cause: Cartridge heaters, especially when stored in humid environments or exposed to moisture during manufacturing or shipping, can accumulate moisture inside their insulation or within the heating element itself.

* Soft Start: Gradually increasing the voltage during initial use (soft starting) helps prevent thermal shock to the heater elements, which can occur if the moisture suddenly evaporates due to rapid heating.

* Bake Out: This involves gradually heating the heater to a moderate temperature (typically around 200-250°C) for a period of time (several hours) to evaporate any trapped moisture from within the heater.

2. Prevent Damage and Performance Issues:

* Thermal Shock: If moisture is not removed and the heater is powered on abruptly, rapid heating can cause thermal shock. This can lead to cracks in the insulation or heating element, reducing the heater’s efficiency and lifespan.
* Corrosion: Moisture inside the heater can promote corrosion of the heating element or metal components over time, potentially leading to electrical failure or reduced heating performance.
* Insulation Breakdown: Moisture can degrade the insulation materials over time, compromising electrical isolation and potentially leading to short circuits or electrical faults.

3. Optimal Performance:

* Properly baked-out heaters perform more reliably and consistently. They reach and maintain the desired temperature more efficiently, ensuring stable operation in the application. 

Consequences of Not Baking Out:

* Reduced Lifespan: Moisture trapped inside the heater can accelerate wear and deterioration of internal components, leading to premature failure.

* Increased Energy Consumption: Heaters with moisture may require more energy to reach and maintain the desired temperature due to inefficient heat transfer.

* Safety Risks: In extreme cases, moisture could cause electrical shorts or faults, posing safety hazards such as electrical shocks or fire.

Soft starting and baking out electrical cartridge heaters are critical steps to ensure their longevity, efficiency, and safe operation. These practices help to eliminate moisture that could otherwise degrade performance, compromise safety, and shorten the heater’s lifespan. Properly preparing heaters before use through soft starting and bake out is therefore essential to maintain their reliability and functionality over time.

About 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. 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.