Precision Heating Solutions for Packaging Machinery

Eliminate weak seals and reduce downtime. Reliable heating elements engineered for VFFS, HFFS, and Thermoforming applications, ensuring consistent package quality in high-speed packaging operations

  • 40% Faster Heat-up Time
  • 99.5% Seal Integrity Rate
  • 30% Energy Savings
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Engineered to fit machinery from major global brands
BOSCH MULTIVAC ISHIDA ILAPAK ULMA TETRA PAK

Why Packaging Engineers Choose HT-Heater

We don't just sell heaters; we engineer solutions that directly address the 6 most critical failures in modern packaging lines.

Solves: Inconsistent Seal Quality

Profiled Heat Distribution

To prevent weak edge seals, we custom-wind the resistance wire tighter at both ends. This compensates for natural heat loss, ensuring the entire sealing bar stays within ±1°C.

  • Uniformity: ±1°C across bar
  • Technology: Distributed Wattage
Solves: Material Compatibility

Adaptive Thermal Control

Switching from PE to Laminates? Our integrated Type J/K thermocouples are positioned for instant feedback, allowing your PID controller to adapt immediately to new setpoints.

  • Sensor Pos: Grounded at Tip
  • Response: Milliseconds
Solves: High-Speed Production

Vibration-Proof Construction

VFFS jaws slam shut 60+ times a minute. Standard crimped leads break. We use swaged-in leads and high-purity MgO compaction to create a solid, shock-resistant unit.

  • Lead Style: Swaged-In (Solid)
  • Durability: High G-Force Rated
Solves: Energy Inefficiency

Precision H7 Fit Efficiency

Loose heaters waste energy heating air gaps. We centerless grind our heaters to H7 tolerance (-0.02mm), ensuring 96%+ direct heat transfer to your tooling block.

  • Tolerance: H7 / g6 Standard
  • Efficiency: Reduced Heat Loss
Solves: Recovery Time

Rapid Thermal Recovery

Don't let line stoppages ruin efficiency. Our high watt density cores (up to 50 W/in²) provide the power surge needed to return to setpoint temperature in seconds.

  • Watt Density: Up to 50 W/in²
  • Ramp-up: Minimizes Downtime
Solves: Maintenance & Cleanability

Wash-Down Ready Designs

For food and pharma lines, we offer IP67-rated moisture barriers. Teflon (PTFE) leads and silicone seals prevent water ingress during daily high-pressure cleaning.

  • Rating: IP65 / IP67
  • Material: SS 304/316 Clean

Specialized Heating Solutions

We provide targeted heating solutions for each stage of the packaging process,

ensuring optimal performance and reliability across diverse packaging applications.

Heat Sealing

Heat Sealing Systems

Precise temperature control is critical for creating strong, consistent seals across various packaging materials and configurations.

  • Recommended Solutions:
  • High-precision band heaters for continuous seal bars
  • Cartridge heaters for impulse sealing applications
  • Ceramic heaters for high-temperature sealing operations
  • Flexible heaters for contoured sealing surfaces
  • Temperature sensors with PID control for exact regulation

Shrink Wrapping Systems

Consistent heat distribution is essential for uniform film shrinkage without damaging products or creating weak points in the packaging.

  • Recommended Solutions:
  • Ceramic infrared heaters for rapid, focused heating
  • Tubular heaters for tunnel applications
  • Quartz heaters for high-intensity radiant heat
  • Multi-zone control systems for different product sizes
  • High-temperature fans for even heat distribution

Thermoforming Packaging Systems

Uniform platen heating is critical for consistent cure rates and product quality in compression molding.

  • Recommended Solutions:
  • Ceramic infrared panels for sheet pre-heating
  • Custom-shaped heaters for specific mold geometries
  • Multi-zone heating for precise temperature profiling
  • High-watt density elements for rapid heat-up
  • Temperature monitoring for process optimization

Label Application Systems

Accurate temperature control ensures proper adhesive activation and label placement without damaging sensitive packaging materials.

  • Recommended Solutions:
  • Small cartridge heaters for compact labeling heads
  • Strip heaters for adhesive activation systems
  • Temperature-controlled rollers for heat-transfer labels
  • Flexible heaters for irregular application surfaces
  • Precision sensors for exact temperature maintenance

Material Compatibility & Temperature Guide

Correct temperature settings are critical for seal strength. Match your heating element profile to your packaging film material below.

Packaging Material Optimal Temp Range Recommended Heater Strategy Sensor Type Critical Challenge
Polyethylene
(LDPE / HDPE) 		120°C - 180°C Low Watt Density
Steady, consistent heat		 Type J Film stretching if too hot
Polypropylene
(OPP / CPP / BOPP) 		160°C - 220°C Medium Watt Density
Fast recovery needed		 Type J Narrow sealing window
Polyester / Laminates
(PET / AL / PE) 		180°C - 250°C Profiled Wattage (High)
Compensate for edge loss		 Type K Leakers at cold spots
Polyvinyl Chloride
(PVC Shrink) 		130°C - 180°C Radiant / Tubular
Non-contact heating		 Type J Toxic fumes if overheated
Nylon / Polyamide
(PA / BOPA) 		190°C - 240°C High Performance Cartridge
Precise temp control		 Type K Moisture absorption issues
Tyvek® / Medical Paper
(Medical Packaging) 		110°C - 130°C Precision Plate Heater
Surface uniformity is key		 RTD Pt100 Burn-through risk
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Engineering Note: Dwell Time Matters

Temperature settings are directly related to your machine speed (Dwell Time). As line speed increases, heater temperature must often be set higher to transfer sufficient energy in a shorter contact time. Ask us for a Thermal Analysis Curve.

Our Cases

Different packaging materials require specific temperature ranges for optimal processing and sealing performance.

Challenge

A leading food packaging manufacturer experienced inconsistent seal quality across their high-speed vertical form-fill-seal machines, resulting in 5% package failure rate and product waste.

Solution

We implemented precision band heaters with multi-zone temperature control and high-accuracy sensors, ensuring ±1°C temperature uniformity across the entire sealing surface.

Results

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Reduced package failure rate to 0.2%, increased line speed by 15%, and achieved 25% energy savings through optimized heating profiles.

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Food Packaging Company

Heat Sealing Application

Challenge

A pharmaceutical company struggled with uneven film shrinkage on their product bundles, creating presentation issues and requiring manual inspection of every package.

Solution

We designed a custom shrink tunnel with ceramic infrared heaters arranged in precise zones, allowing targeted heating for different product sizes and film types.

Results

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Achieved uniform shrinkage across all product configurations, eliminated manual inspection requirements, and reduced energy consumption by 30% through zone optimization.

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Pharmaceutical Manufacturer

Shrink Wrapping Application

Challenge

A beverage company producing PET bottle sleeves faced material webbing and inconsistent forming due to temperature variations across their thermoforming ovens.

Solution

We replaced their standard heating elements with custom infrared panels featuring precise temperature zoning and advanced reflectors for optimal heat distribution.

Results

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Eliminated material webbing issues, improved forming consistency by 40%, and reduced scrap rate from 8% to less than 1%, saving approximately $50,000 annually in material costs.

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Beverage Packaging Facility

Thermoforming Application

Common Questions about Packaging Heaters

Technical answers for engineers and procurement managers. Can't find what you need? Contact our engineering team.

Why do my cartridge heaters fail prematurely on VFFS machines?

Premature failure in VFFS sealing jaws is usually caused by high-frequency vibration breaking the internal leads or moisture ingress. We solve this by using swaged-in internal leads (vibration-proof) and high-purity MgO compaction to withstand rapid cycling.

How do I determine the correct wattage density for my sealing bar?

Wattage density (W/in²) depends on your operating temperature and cycle speed. A general rule for packaging is 30-50 W/in². However, we highly recommend Distributed Wattage (winding tighter at the ends) to prevent "cold ends" and ensure consistent seal integrity across the full package width.

Can you manufacture a replacement heater without a part number?

Yes. We specialize in reverse engineering OEM parts. Simply send us a photo of the old heater along with the Diameter, Length, Voltage, and Wattage. If the specs are worn off, you can mail us the failed unit for physical analysis, and we will build a matching or improved replacement.

What is the lead time for custom packaging heating elements?

We understand that downtime costs money. Our standard production time for custom orders is 5-7 business days. For emergency breakdown situations, we offer a 48-hour rush production service to get your line back up and running.

Why is the fit (tolerance) so important for heater life?

A loose heater creates an air gap, which acts as an insulator. This causes the heater core to overheat and burn out while the sealing bar remains cold. Our heaters are centerless ground to H7 / g6 tolerance (-0.02mm) to ensure a tight fit for maximum heat transfer and longevity.

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