Core Value

In precision industrial processes—such as plastics extrusion, exothermic chemical blending, and pharmaceutical jacketed reactors—simply applying heat is often insufficient. Mechanical friction from pumps or exothermic chemical reactions can cause the fluid temperature to rapidly overshoot the designated setpoint. To maintain absolute thermal stability, the system requires both a heat source to reach operating temperature and a cooling mechanism to pull excess heat out of the fluid.

This Industrial 380V Screw Plug Immersion Heater With Cooling Coil resolves this thermodynamic challenge by consolidating both functions. The central tubular elements inject high-wattage 380V thermal energy into the fluid, while the integrated helical coil allows a secondary cooling medium (such as chilled water or glycol) to be circulated directly through the hot zone. This enables immediate thermal suppression without requiring a separate heat exchanger or a second mounting port in the vessel.

To manage the mechanical stress of pumped fluid circulation, the multi-tube heating bundle is structurally reinforced with a mid-span metal retaining band. This spacer permanently locks the long tubes into a fixed matrix, preventing flow-induced vibration and eliminating friction wear between the elements.

Environmental protection at the electrical junction is critical in demanding industrial facilities. Rather than utilizing exposed terminals, this heater is equipped with a protective cylindrical terminal enclosure. This housing utilizes a durable black strain-relief cable gland that hermetically seals the entry point of the thick black power cable, completely safeguarding the internal electrical connections from moisture ingress, chemical splashing, and high-pressure washdowns.

✓ Dual-Action Thermal Control: Combines high-power 380V heating and active fluid cooling within a single, space-saving tank penetration.

✓ Integrated Helical Cooling Coil: Allows the circulation of chilled liquids to rapidly suppress thermal overshoot in exothermic reactions.

✓ Vibration-Resistant Bundle: A welded mid-span retaining band secures the tubular elements together, preventing mechanical fatigue in high-velocity flows.

✓ Sealed Terminal Enclosure: The cylindrical cap and black cable gland protect the internal wiring from industrial moisture and fluid leaks.

✓ Pre-Wired Power Integration: Features a robust black power cable exiting the enclosure, radically accelerating OEM factory wiring and field installation.

Technical Specifications & Customization Options

Industrial Applications & Solutions

This highly specialized dual-function immersion heater is the specified thermal core for precision fluid equipment:

• Temperature Control Units (TCUs): The essential component for water and oil mold temperature controllers used in high-precision plastic injection molding and die casting.

• Chemical & Pharmaceutical Reactors: Regulates the temperature of jacketed vessels, providing heat for the initial reaction and cooling to manage exothermic runaways.

• Industrial Oil Baths: Maintains exact viscosity and thermal stability for heavy machine oils, lubricants, and calibration fluids.

• Extrusion Barrel Heating/Cooling: Stabilizes the immense heat generated by shear friction during high-speed plastic and rubber extrusion processes.

Hongtai Heater Factory Advantage: Why Choose Flanged Heating Elements?

Installation & Handling Guidelines

• Mandatory Complete Submergence: The active heating tubes and the integrated cooling coil must be completely submerged in the primary tank fluid before 380V power is applied. Dry-firing will instantly melt the heating elements.

• Cooling Coil Plumbing: The inlet and outlet of the cooling coil must be connected to a properly rated cooling supply (e.g., chilled water or a heat exchanger). Ensure the cooling circuit utilizes pressure relief valves, as fluid trapped inside the coil can rapidly expand and burst the tubing when the heating elements are active.

• Use the Hex Head Only: When threading the unit into the boiler coupling, only apply torque to the machined stainless steel hex head. Never grip the cylindrical terminal enclosure, the cooling coil, or the black power cable for leverage, as this will destroy the internal seals and wiring.

• Thread Sealing: Wrap the threads of the hex plug tightly with high-temperature PTFE (Teflon) tape or an industrial liquid thread sealant to guarantee a drip-free seal against commercial vessel pressures.

Customer Success Stories

Case 1:

Plastics Injection Molding TCU Manufacturer (Germany)

• Application: High-precision Temperature Control Units (TCUs) regulating mold temperatures for automotive plastic components.

• Challenge: Rapid exothermic shifts and mechanical shear friction from high-speed pumps were causing fluid temperatures to overshoot setpoints, leading to defective injection-molded parts. Furthermore, using separate ports for heating and cooling created layout and leakage issues in compact machine chassis.

• Solution: Partnered with HT HEATER to integrate the Industrial 380V Screw Plug Immersion Heater with Cooling Coil. The dual-action unit allowed 380V heating and active fluid cooling through a single tank penetration.

• Results: PRECISE PID TEMPERATURE STABILITY. The integrated helical cooling coil rapidly suppressed thermal overshoots, while the sealed terminal enclosure and cable gland completely protected the wiring from cooling-water condensation and splashing, drastically lowering machine downtime.

Case 2:

Pharmaceutical Reactor System Integrator (USA)

• Application: Jacketed chemical synthesis and blending vessels requiring strict multi-stage thermal profiles.

• Challenge: The chemical blending process alternated between endothermic reactions requiring intense heating and sudden exothermic spikes requiring rapid cooling, all within a heavily restricted tank geometry that only permitted a single threaded port.

• Solution: HT Heater engineered a custom-length screw plug heater featuring both a multi-tube heating bundle and an outer helical cooling loop, all secured via a heavy stainless steel hex plug.

• Results: SEAMLESS DUAL-FUNCTION PERFORMANCE. The integrated system provided the necessary thermal range without requiring complex secondary plumbing or structural vessel modifications. The mid-span retaining bands successfully neutralized turbulent pump vibrations, ensuring a reliable, long-term service life.

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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