Lightweight Industrial Heating Solution for Plastic Processing
Core Value: Lightweight aluminum band heater offers excellent thermal conductivity and corrosion resistance for cost-effective barrel heating in injection molding and extrusion applications. Aluminum sheath provides 2× better heat transfer than stainless steel while reducing weight by 60%. Ideal for applications requiring frequent heater changes or where equipment weight is a concern. BACKED BY 30+ YEARS MANUFACTURING EXPERIENCE and UNDERGOES MULTIPLE RIGOROUS QUALITY CHECKS for reliable industrial performance.
- ✓ Lightweight Design: 60% weight reduction vs steel
- ✓ Excellent Conductivity: 2× better heat transfer
- ✓ Corrosion Resistant: Natural aluminum oxide layer
- ✓ Cost-Effective: Competitive pricing for standard apps
- ✓ Fast Heat-Up: Reduced energy consumption
- ✓ Easy Handling: Lightweight for maintenance
- ✓ Reliable Quality: 30+ YEARS MANUFACTURING EXPERIENCE
- ✓ Quality Assured: UNDERGOES MULTIPLE RIGOROUS QUALITY CHECKS
- ✓ Global Standards: CE, LVD, RoHS, ISO 9001 certified
Technical Specifications & Performance Data
| Parameter | Standard Value | Customizable Range | Notes |
|---|---|---|---|
| Heater Width | 40mm (1.57″) standard | 30mm – 100mm | Standard modular sizes |
| Power Rating | 1kW (±5% tolerance) | 0.5kW – 3kW | Wattage per unit length |
| Voltage Rating | 240V AC 1-phase | 120V – 480V | 50/60Hz compatible |
| Barrel Diameter | 65mm (2.56″) standard | 30mm – 400mm | Custom diameters available |
| Max Temperature | 400°C continuous | 450°C (special design) | Aluminum limit |
| Thermal Conductivity | 205 W/mK (aluminum) | Anodized option | 2× better than steel |
| Watt Density | 5.5 W/cm² (optimized) | 4 – 8 W/cm² | Uniform distribution |
| Sheath Material | 6061-T6 aluminum | Anodized coating | Lightweight & durable |
| Insulation | High-grade mica | Ceramic fiber option | Electrical isolation |
| Weight Reduction | 60% lighter than steel | 2.7 vs 7.85 g/cm³ | Easier handling |
| Clamp Type | Barrel nut with SS strap | Full circle, hinge type | Secure mounting |
| Leads | Fiberglass insulated 300mm | Nickel wire, SS braid | 250°C rated standard |
| Terminal Box | Optional metal enclosure | IP54 protection | Electrical safety |
| Ground Protection | Integrated ground strap | Continuous ground path | Safety compliance |
| Warranty | 1 Year Standard | Quality assured | COMPREHENSIVE QUALITY ASSURANCE |
Industrial Applications & Solutions
- Injection Molding Barrels: General-purpose plastic processing. Lightweight design reduces machine load. Fast heat-up reduces startup time. Suitable for PP, PE, PS materials. Cost-effective for multi-zone heating.
- Extrusion Applications: Profile and sheet extrusion. Excellent for temperature-sensitive polymers. Even heat distribution ensures consistent melt. Reduces energy consumption by 15%. Ideal for large diameter barrels.
- Blow Molding: Continuous extrusion blow molding. Lightweight construction for oscillating heads. Corrosion-resistant for outdoor applications. Reliable for 24/7 production. Easy maintenance access.
- Packaging Machinery: Hot melt adhesive systems. Fast response for intermittent operation. Lightweight for robotic applications. Cost-effective for multiple stations. Long service life.
- Food Processing: Moderate temperature food-grade heating. Anodized coating for corrosion resistance. Complies with food safety requirements. Easy to clean surfaces. Reliable for batch processing.
- Chemical Processing: Non-corrosive chemical heating. Aluminum compatible with many chemicals. Lightweight for vessel mounting. Good thermal efficiency. Suitable for moderate temperatures.
HT-Heater vs Standard Market Heaters
| Feature | HT-Heater | Standard Market | Your Advantage |
|---|---|---|---|
| Weight | 60% lighter than steel | Heavy steel construction | Easy installation & handling |
| Thermal Conductivity | 205 W/mK (aluminum) | 16 W/mK (steel) | 2× faster heat transfer |
| Heat-up Time | 20% faster than steel | Slower response | Energy savings |
| Corrosion Resistance | Natural oxide layer | Prone to rust | Longer life in humid environments |
| Material Grade | 6061-T6 structural aluminum | Soft commercial grade | Mechanical durability |
| Anodizing Option | Available for harsh environments | Not offered | Enhanced corrosion protection |
| Manufacturing Experience | 30+ YEARS EXPERIENCE | Less than 10 years | Proven reliability |
| Quality Assurance | UNDERGOES MULTIPLE RIGOROUS QUALITY CHECKS | Basic continuity test | ZERO DEFECT DELIVERY |
Installation & Integration Guidelines
- Barrel Mounting: Clean barrel surface thoroughly. Position heater in heating zone. Tighten barrel nut evenly to ensure full contact. Avoid over-tightening (max torque 4Nm). Gap between heater ends: 3-5mm. Thermal paste optional but improves performance. Allow 5mm clearance from machine guards.
- Electrical Connection: Standard voltage supply (240V typical). Dedicated circuit with appropriate breaker. Connect to terminal block or leads directly. Use high-temp terminal lugs. Fiberglass leads rated 250°C – keep away from hot surfaces. Ground connection mandatory for safety.
- Temperature Control: External PID controller recommended. J-type or K-type thermocouple placement. Thermocouple should be 10mm from heater surface. Auto-tune PID for optimal performance. Solid-state relay (SSR) switching. Avoid mechanical relays for long life.
- Safety Systems: Over-temperature protection recommended. Ground fault protection for personnel safety. Thermal insulation covers reduce heat loss. Lockout/tagout procedures for maintenance. Regular inspection of clamp tightness.
Customer Success Stories
Case 1: Large Extrusion Manufacturer (USA)
Application: 500mm diameter HDPE pipe extrusion, 24/7 operation
Challenge: Heavy steel heaters causing worker fatigue during changes, slow heat-up on large barrel
Solution: Aluminum band heaters 1kW, 60mm width, 12 zones
Results: HEATER CHANGES NOW TAKE 50% LESS TIME. Heat-up improved by 25%. Worker injury risk reduced significantly.
Client Quote: “HT-Heater UNDERGOES MULTIPLE RIGOROUS QUALITY CHECKS – the lightweight design is a game-changer for our large machines.” – Maintenance Supervisor
Case 2: Multi-Plant Molder (Mexico)
Application: General purpose injection molding across 5 facilities
Challenge: Standardizing heater specifications, reducing spare parts inventory
Solution: Standard aluminum band heaters in 40mm and 60mm, standard diameters, 800+ units
Results:SPARE PARTS INVENTORY REDUCED BY 60%. Standardization simplified maintenance. Cost savings $45,000 annually.
Client Quote: “30+ YEARS MANUFACTURING EXPERIENCE shows in the consistent quality across all our plants. Perfect standardization partner.” – Corporate Engineering Manager
Case 3: Food Packaging OEM (Italy)
Application: Hot melt glue system for food carton sealing
Challenge: Corrosion in humid washdown environment, FDA compliance needed
Solution: Anodized aluminum band heaters, 40mm width, 150 units
Results: CORROSION ELIMINATED. FDA approval achieved. Heater life increased from 1 to 3+ years.
Client Quote: “The anodized option and QUALITY ASSURANCE were exactly what we needed. Outstanding solution.” – Quality Director
Pricing & Procurement Options
Sample Orders: Available for testing. Samples are paid. Contact sales for sample pricing and delivery. All samples UNDERGO MULTIPLE RIGOROUS QUALITY CHECKS.
Standard Production: MOQ 10 pieces. BACKED BY 30+ YEARS MANUFACTURING EXPERIENCE ensures consistent quality. Volume discounts for 50+ units. Standard models in stock.
Custom Configurations: Custom diameters, wattages, voltages, widths, anodizing options. Thermocouple integration available. Engineering support included. All custom heaters UNDERGO MULTIPLE RIGOROUS QUALITY CHECKS.
Lead Times: Standard: 7-10 days production. Custom: 10-15 days. Samples: 5-7 days. Rush service available for urgent requirements.
Global Logistics: Worldwide shipping via UPS, DHL, FedEx, EMS, TNT or the shipping agent as your request. Every shipment backed by 30+ YEARS MANUFACTURING EXPERIENCE.
Global Certifications & Compliance
- CE Marking
Conforms to European directives
Health, safety, environmental protection - LVD Compliance
Low Voltage Directive
Electrical safety requirements - RoHS Compliant
Restriction of Hazardous Substances
Environmentally safe materials - ISO 9001
Quality Management System
Rigorous quality control processes
Quality Documentation: Certificate of Conformity and test reports available. Every unit UNDERGOES MULTIPLE RIGOROUS QUALITY CHECKS before shipment.
Comprehensive After-Sales Support
Warranty: 1 Year Standard Warranty.
Technical Support: Application engineering for aluminum heater selection. Temperature control integration guidance. Installation troubleshooting assistance.
Service Network: BACKED BY 30+ YEARS MANUFACTURING EXPERIENCE. UNDERGOES MULTIPLE RIGOROUS QUALITY CHECKS ensures reliability. Global technical support available.
Quality Commitment: Material traceability documentation. Replacement parts in stock. Repair evaluation service provided.
Ready for Lightweight Heating Solutions?
Next Steps:
- 📧 Request Custom Quote – Specify your barrel diameter and voltage
- 📄 Download Weight Comparison – Weight savings data
- 🔧 Free Thermal Analysis – Optimize your heating efficiency
- 📦 Order Lightweight Samples – Feel the difference
- 📞 Contact Aluminum Heating Experts – Response within 2 hours
HT-Heater.com – Lightweight Industrial Heating Solutions
30+ YEARS MANUFACTURING EXPERIENCE | UNDERGOES MULTIPLE RIGOROUS QUALITY CHECKS | CE LVD RoHS ISO 9001
Aluminum Band Heaters | Lightweight | Anodized Options | Global Support
