Band Heater
Your Leading Band Heater Supplier
We are committed to provide system solutions for plastic industry and offers high-end products like Shut off Nozzles, Plasticizing Screw Barrel, Tip Assembly and Tie Bar. After years of technical precipitation, Rootier is currently the only Chinese-based supplier providing full series injection nozzle solutions like shut off nozzle, mixing nozzle and filter nozzles. We have lot ready stock screw barrel for some commonly used IMM like Nissei, Sumitomo, Fanuc, Victor machines, which suitable for high Glass Fiber filled plastics processing with unique solutions to increase lifetime and performance.
Why Choose Us?
High quality
We have 100% quality guarantee to customers. We will be responsible for any quality problem.
Competitive price
Our products are complete in variety, good in quality, reasonable in price.
After-sale service
Good after-sale service, handling the customer complaint and solve problem for customers.
Fast delivery
Huge production capacity to ensure in time delivery and transport to the destination in the first time.
Band heaters are ring-shaped devices that clamp around and externally heat cylindrical surfaces. All these heaters use electrical conduction, although some types may use a combination of electrical conduction and radiation. Most heaters are made with metals because they are exceptional conductors.
Benefits of Band Heater
High thermal conductivity
Undoubtedly, one of the main advantages of band heaters is that they’re excellent at conducting high temperatures and transferring heat to the right areas of a machine. This makes them highly efficient heaters that can operate at extremely high temperatures, making them suitable for all kinds of applications.
Consistent heat distribution
As well as being great at conducting heat and withstanding high temperatures, band heaters also ensure consistent heating across an entire service. This uniform level of heating is often required in machines where precise temperatures are necessary.
Durability
All band heaters are manufactured using the finest quality materials, meaning they’re extremely durable and resistant to wear and tear. Furthermore, this durability makes them a great choice for machines that may also use corrosive materials or abrasive substances (although in this case a heater of sealed construction should be specified).
Increased efficiency
Not only do band heaters offer efficient heat distribution in a uniform fashion, but they also consume less energy than other components. This means energy loss is reduced and they’re more cost effective, resulting in a product that is more efficient overall.
Types of Band Heater
1.Mica band heaters
Mica bands are inexpensive and easy to install. They derive their name from their electric insulator, “mica.” Mica bands are stocked in hundreds of sizes and can be custom manufactured in as little as one day. They have a tight sheath to barrel fit to avoid premature burnout. We do not recommend mica bands in high temperature or high watt density applications.
2.Ceramic band heaters
Ceramic bands provide long life and lower energy costs. They provide efficient heat transfer without being affected by surface irregularities or loose fit. They can be manufactured in as little as one day. Ceramic bands function well in high temperature applications.
3.Extruded aluminum band heaters
Extruded aluminum bands are very rugged. They employ tubular elements snapped into an extruded aluminum case. They provide excellent heat transfer and have a very long life. Extruded aluminum bands cannot handle temperatures above 650° F.
4.Cast band heaters
Cast band heaters are very expensive but can last 10 years or longer. They are extremely rugged. Cast heaters operate in low watt densities but can work at higher temperature. Cast heaters have a very long lead time. They are available with cooling fins or tubes. Typically these heaters are cast in bronze or aluminum.
5.Mini coiled heaters
Mini coiled heaters provide worry-free heat for hot runner systems. These heaters are typically sealed to virtually eliminate failures due to contamination. Axial clamps provide easy installation. These heaters can handle higher temperatures.
6.Coil heaters
Coil heaters are low profile heaters that are easy to install in the tight environment of multiple-gate molds. Heat is conducted from the entire 350 degree circumference (mica bands are not). Optional thermocouple provides temperature measurement capabilities.
Application of Band Heater
Plastics
In plastic molding, band heaters are used to heat and mold plastic materials. The key factor in their use is the precision control of the heating process, which ensures the proper level of heat for shaping a product. They help soften materials for proper shaping.
Food production
As every chef can tell you, proper heating is an essential for preparing food in order to reach the proper consistency and flavor. Band heaters help heat ingredients to the correct temperature for mixing and assist in maintaining the temperature. Since band heaters are able to provide constant even and uniform heat, they help ensure that food is cooked and heated evenly.
Packaging
A common use for band heaters in packaging is sealing and shrinking packaging materials such that items to be shipped are held tightly in place. Since band heaters heat up quickly, they are ideal for the process due to the many packages that have to be handled at once.
Pharmaceuticals
The use of band heaters in the pharmaceutical industry is very similar to their use in the food industry since temperature control is critical to the production of medicines. Precision temperature control helps produce uncontaminated medications that have the proper consistency and texture.
Chemical processing
Drum band heaters are used by chemical processing to keep chemicals at a desired temperature. They help reduce viscosity, help with heat transfer, and keep liquids in liquid form.
Industrial equipment heating
The heating of industrial equipment is a common use for band heaters due to their flexibility and ease of installation. They are used to regulate chemical reactions, maintain viscosity, and prevent freezing in storage tanks, reactors, pipes, and processing tools.
Metal casting
The use of band heaters for metal casting is very similar to their use for plastic forming or injection. They are used to heat molds, keep materials heated, and help casting tools reach the appropriate temperatures for pouring molten metals.
Components of Band Heater
The helically wound heating coil is the actual resistance which is where the electrical load occurs. The most common type of metal alloy used for this purpose is a Nickel-Chromium mixture, also known as Nichrome. The Nichrome wire is wound around a ceramic core, and the number of spirals per inch vary according to the requested watt density. Potential from an alternating current source, which can either be 2 phase or 3 phase, flows through the coiled Nichrome wire, heating up the wire, which in turn, heats the cartridge heater sheath.
Built in ceramic fiber insulation is used to prevent the Nichrome coil to contact the sheath. If such event happened, it would ground the resistance and produce a catastrophic short-circuit, resulting in a melted sheath and a major equipment failure. To prevent the coil from touching the sheath, the coil is strung through custom designed ceramic insulating bricks.
The housing is the part of the ceramic band heater which holds the ceramic knuckles inside the band together. Several metal alloys are used, for the housing. The most common types of housings are made from stainless steel or stainless steel alloy.
Since ceramic band heaters are installed in a wide variety of machines, manufacturers must design the heaters to meet certain clearances. The knuckle band heaters might be terminated with terminal box with screw terminals and or leads coming out straight, or in a right angle. Also, manufacturer must be careful that the leads are not exposed to temperatures higher than the maximum rating for the lead wire. In order to prevent lead wire damage from temperature, movement or contamination, the lead wire can be protected with metal conduit or braided metal.
Process of Band Heater
Determine the specifications: The first step is to determine the dimensions and power requirements of the band heater. This will depend on the size and shape of the object you want to heat, as well as the temperature range you need.
Select the heating element: The heating element is the part of the band heater that generates the heat. There are many types of heating elements available, including nichrome wire, ceramic, and mica. Nichrome wire is a common choice for band heaters because it's inexpensive and has a high resistance, which allows it to generate a lot of heat in a small space.
Choose the insulation material: The insulation material is what separates the heating element from the object being heated and prevents heat loss. Common insulation materials for band heaters include ceramic fiber, mica, and fiberglass.
Create the band: To create the band, you'll need to cut a strip of insulation material to the appropriate length and width for your specifications. Then, you'll need to wrap the heating element around the insulation, making sure it's evenly spaced and secured in place.
Install the wiring: The heating element will need to be wired to a power source. You'll need to attach wires to the ends of the heating element and then connect them to a power source using a plug or other connector.
Test the band heater: Once everything is assembled, you'll need to test the band heater to make sure it's working properly. Check the temperature and ensure that it's heating evenly around the object.
1. Regular visual inspection
Perform regular visual inspections of your band heaters to ensure their optimal performance. During these inspections, carefully observe the surface for any indications of wear, damage, or discoloration. Recognizing these issues early on is crucial as it can help prevent further damage and ensure uninterrupted operation of your heaters.
2. Clean surrounding area
Keeping the surroundings clean can have a significant impact on the performance of band heaters. Dust, debris, and contaminants can accumulate on the heaters, affecting their efficiency. Regularly clean the area around the heaters to prevent these particles from interfering with their operation.
3. Proper installation
Proper installation is crucial to ensure the efficient operation of band heaters. It is important to securely install and accurately position them on the equipment. Improper installation can result in uneven heating and a shortened lifespan. Take the necessary steps to ensure correct installation for optimal performance.
4. Monitor operating temperatures
To prevent overheating and premature failure, it is essential to regularly monitor the operating temperatures of band heaters. Operating these heaters beyond their designed capacity can result in damage. It is important to ensure that the operating temperatures remain within the recommended range for optimal performance and longevity.
5. Avoid overloading
To maximize the lifespan of your band heaters, it is crucial to avoid overloading them. By exceeding the recommended voltage or wattage, you risk causing rapid deterioration in their performance. It is important to adhere strictly to the manufacturer’s specifications for voltage and wattage to prevent overheating.
6. Regular cleaning
One important aspect of maintaining efficient heat transfer and preventing hotspots is regular cleaning of band heaters. Dust and contaminants can build up over time, affecting their performance. To address this issue, it is recommended to periodically clean the surface of the heaters using a soft brush or compressed air.
7. Timely replacement
It is important to replace band heaters in a timely manner. These heaters have a limited lifespan, even with proper maintenance. Monitor their usage and replace them promptly if you notice any signs of wear, reduced efficiency, or irreparable damage. By replacing them promptly, you can ensure uninterrupted operations.
Band heaters generate most of their heat via the process of electrical conduction. Heating bands are made up of metal filaments that are encased in a protective covering. That covering is the component that converts electrical current into heat. Following that, the heating band will transmit the heat energy to another body using a mechanism that is under regulated conditions. The heating band will accomplish this by either conduction or radiation.
How to Extend the Life of Band Heaters
Eliminate air pockets - You can break a band heater easily by allowing any amount of air between metal surfaces. That’s because they conduct heat by transferring the electrical current through those metals, and if there’s an anomaly present, you’ll suffer inefficiency, and wear out the material. Sometimes you can resolve this by tapping the outside with a rubber mallet.
Ensure proper diameter - If your band is even a little too big for the intended barrel, you could run into trouble. A band that’s one inch longer could create a band circumference that’s two or three inches too wide, forcing you to tighten it more, thus contributing to poor adherence.
Prevent contamination - Band heaters are no different from the rest of your factory equipment. If they come into contact with chemicals, rubber, oil, plastic, water, or other foreign material, they can damage the band. For facilities that cannot guarantee a sufficiently clean environment, it’s better to select a MICA band over ceramic options.
Use the correct wattage - It should come as no surprise that heating equipment will deteriorate faster if you use more wattage than they’re designed to handle. You should never purchase products from manufacturers who don’t specify a maximum wattage. You can see from our website how we offer band heaters with a maximum wattage of either 70 or 100 watts PSI.
Never use inferior products - Besides wattage issues, you’d be doing yourself a disservice to buy “bargain” band heaters. Lower-quality heaters could have the wrong size resistive wire, poor ceramic positioning (between metal plates), and other design flaws.
How Do You Test a Band Heater?
To ensure optimal performance, you should always test your band heater before you install it. If your heater is already installed, but you’re not sure whether it’s performing optimally, a test will help you better understand the answer. For safe testing and less downtime, we recommend the following steps:
Turn off the power going to the heater.
Disconnect the heater’s lead wires.
After that, you must locate the number that is engraved on your heater; this number specifies the voltage and wattage.
The next step is for you to measure the resistance between the two post terminals or the two lead wires. It depends on the type of heater that you have. The heater’s resistance should be approximately the heater’s voltage squared divided by the heater’s wattage; the formula for this is R = V2 / W.
After you have the total resistance number (measured in ohms), you’ll want to then perform another test using an ohmmeter.
The standard tolerances are as follows: If your heater is operating at room temperature, the resistance measured by the ohmmeter can be 10% less or 5% greater than the total you calculated using the formula above. If the resistance value falls outside of this range, your heater is not operating as it should be.
Our Factory
We have two factories with about 9000 square meters construction area located in Zhoushan. Our engineers are experienced in all kinds of plastic processing design and application. Our production capacities can reach 1500 screw barrel sets monthly that enable us to deliver products to our customers in a short time.
