Core Value

In commercial water heating applications—such as steam tables, coffee urns, commercial dishwashers, and brewing kettles—space is often severely restricted. A standard straight heating rod cannot deliver the required wattage without being excessively long.

The Folded U-Shape Tubular Immersion Heater solves this spatial challenge. By folding the tubular element back on itself (as seen in CMY_0694.jpg), HT Heater engineers have doubled the active heating surface area within the same immersion length. This lowers the overall watt density (surface load) of the heater, which significantly reduces the rate of calcium scale buildup in hard-water areas and prevents the element from prematurely burning out.

The critical mounting points are engineered for absolute leak prevention. The heater features heavy-duty threaded bulkhead fittings (often machined from brass or stainless steel) that are silver-brazed or TIG-welded directly to the tubular sheath. Combined with high-temperature silicone or PTFE washers and sturdy locknuts, these fittings create a pressure-tight mechanical seal through the metal wall of the water tank.

Internally, the heater is powered by a premium Ni80Cr20 resistance coil, perfectly centered and insulated by high-tonnage rotary-swaged Magnesium Oxide (MgO) powder. This robust internal construction ensures maximum dielectric strength and instantaneous heat transfer to the surrounding liquid.

• ✓ Maximized Surface Area: Folded multi-U geometry delivers high wattage (e.g., 2kW – 6kW) in confined tank spaces while maintaining a safe watt density.
• ✓ Leak-Proof Bulkhead Mounting: Precision-threaded fittings with included sealing washers and locknuts ensure a watertight seal through the tank wall.
• ✓ Corrosion & Scale Resistance: Available in pure Copper, SUS304, SUS316L, or Incoloy 840 to resist water scaling and chemical corrosion.
• ✓ Robust Terminal Studs: Heavy-duty threaded electrical studs provide a secure, vibration-proof connection for ring terminals, eliminating the melting risk of cheap spade connectors.
• ✓ Direct OEM Manufacturing: Fully customizable immersion lengths, wattages, and thread sizes supplied directly by HT HEATER.

Technical Specifications & Performance Data

Industrial Applications & Solutions

This versatile bulkhead immersion heater is the thermal engine for a vast array of fluid heating equipment:

• Commercial Catering Equipment: Powers steam tables, bain-maries, soup kettles, and commercial coffee/tea urns.

• Sanitation & Warewashing: Installed in the sump tanks of commercial under-counter and conveyor dishwashers to maintain critical sanitizing water temperatures (82°C+).

• Industrial Cleaning Vats: Heats aqueous alkaline solutions in ultrasonic parts cleaners and localized degreasing tanks.

• Beverage & Brewing: Provides direct immersion boiling for micro-brewery kettles, hot liquor tanks (HLTs), and distillation boilers.

• Medical & Laboratory: Delivers precise heating for laboratory water baths and medical sterilization autoclaves.

HT HEATER Advantage: Why Choose Our Immersion Heaters?

Installation & Handling Guidelines

• Mandatory Complete Submergence: The entire active heating length of the Folded U-Shape Tubular Immersion Heater must be completely submerged in water before the power is turned on. Dry-firing will cause the element to glow red-hot and burn out within minutes, voiding all warranties.

• Proper Washer Sealing: Place the high-temperature sealing washer on the inside of the tank wall (between the tank and the heater’s fixed flange). Slide the threaded fitting through the hole, and tighten the locknut firmly on the outside of the tank. Do not overtighten to the point of tearing the silicone washer.

• Firm Electrical Connections: Use appropriately sized ring terminals on your supply wires and secure them tightly to the threaded studs using two wrenches (one to hold the bottom nut, one to tighten the top). Loose electrical connections will arc, generate extreme heat, and melt the terminal block.

• Routine Descaling: In commercial water heating, calcium and magnesium scale will inevitably build up on the heater sheath. This scale acts as an insulator. To prevent the heater from overheating and failing, establish a routine maintenance schedule to descale the element using a commercial descaling acid or vinegar solution.

Customer Success Stories

Case 1:

Commercial Dishwasher OEM (Italy)

• Application: Sump and booster heaters for high-volume commercial flight-type dishwashers.

• Challenge: The high concentration of industrial detergents and hard water was causing competitor heaters to corrode at the bulkhead weld, leading to catastrophic leaks into the electrical control panel.

• Solution: Transitioned to HT HEATER‘s Commercial Folded U-Shape Tubular Immersion Heaters constructed from SUS316L stainless steel, featuring deeply TIG-welded threaded fittings rather than standard brazing.

• Results: LEAKS COMPLETELY ELIMINATED. The deep TIG welds and upgraded alloy withstood the harsh detergent chemicals, increasing the lifespan of the OEM dishwashers and drastically reducing field service calls.

Case 2:

Micro-Brewery Equipment Manufacturer (USA)

• Application: 55-gallon electric brewing kettles and Hot Liquor Tanks (HLTs).

• Challenge: Brewers needed to boil large volumes of sweet wort quickly without scorching the sugars. Standard high-wattage straight elements scorched the liquid due to excessively high surface temperatures.

• Solution: Integrated HT Heater’s folded multi-U shape elements. The folded design allowed us to pack 6000W into the small kettle diameter while drastically expanding the surface area to achieve an ultra-low watt density.

• Results: VIGOROUS BOILS WITH ZERO SCORCHING. The expanded geometry transferred heat gently but rapidly, preserving the flavor profile of the beer and making the kettles highly sought-after by craft brewers.

Pricing & Procurement Options

• OEM Customization: Tailored shapes, custom cutout holes for pipe nozzles, specialized voltage/wattage configurations, and custom strap lengths.
• Lead Times: Custom samples: 3–5 working days. Bulk production orders: 8–12 working days upon technical drawing sign-off.
• Packaging & Shipping: Individually bagged with protective foam padding and packed into heavy-duty 5-ply export cartons to prevent bending or lead wire stress during international transit.
• Minimum Order Quantity (MOQ): Low MOQ starting at 5–10 units for custom dimensions; competitive volume pricing tiers for equipment manufacturers.

Global Certifications & Compliance

• CE Marking
  Fully compliant with European safety and environmental standards.
• LVD Compliance
  Low Voltage Directive tested for continuous thermal load safety.
• RoHS Compliant
  Constructed using environmentally safe, lead-controlled brass alloys.
• ISO 9001
  Certified quality control covering CNC machining, coil pressing, and electrical testing.

Quality Documentation: Certificate of Conformity (COC) and insulation resistance test reports included.

Comprehensive After-Sales Support

• • Warranty: 1-Year Comprehensive Warranty covering internal heating element and built-in sensor.

  • Technical Support: Application engineers available for wattage distribution calculation, thermocouple calibration, and nozzle fitting assistance.

  • Global Response Network: BACKED BY 30+ YEARS MANUFACTURING EXPERIENCE with technical inquiry feedback within 2 hours.

Ready to Optimize Your Injection Molding?

Next Steps:

• 📧 Request Custom Quote – Send your nozzle dimensions, wattage, voltage, and HT-CLW-450 drawing requirements.
• 🔧 Free Design Consultation – Work with our thermal engineers to optimize heat distribution and lead insulation.
• 📦 Order Test Samples – Evaluate thermal performance on your injection molding machine.
• 📞 Contact Hot Runner Experts – Response within 2 hours

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