Cast Band Heaters

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  Cast-In Band Heaters  

Although Proheat is widely recognized as the industry leader in Cast-In heater/coolers for the plastics industry, our capabilities and the application possibilities for utilizing Cast-In Heater Technology extend far beyond the scope of plastics machinery. Proheat has set industry standards by creating custom designed Cast-In Heaters of every imaginable size, shape and electrical rating that can safely and practically address the diversified requirements of industrial and commercial markets.

Design Specifications

 

Casting Process

Permanent Molds: For large quantity runs, this process uses steel or cast iron molds and yields a superior finish and enhanced cosmetic value.

No-Bake Sand Molds: For small quantity runs, this process requires wooden patterns. This is an economical, fast means of manufacturing tooling for lower volume casting requirements and for making prototypes.

Cast Alloys
  Alloy Maximum Surface Temperature  
  Aluminum 319 (Standard)   700°F (375°C)  
  Brass 1200°F (649°C)  
  Bronze 1350°F (732°C)  

Clamping Styles
Strap Clamping: 20 Gauge Type 430 Stainless Steel Straps with 1/4"-20 Bolts and Barrel Nuts—3/4", and 1/4" wide standard
Bolt Clamping: Specify Fastener Requirements  

Dimensional
  Minimum Inside Diameter
Maximum Inside Diameter
Minimum Width
Maximum Width
Minimum Length
Maximum Length
Finish
Gap		 1"
48"
2 1/2"
36"
2"
36"
125 RMS Standard
1/4" top and bottom or to customer specification		  

 
Electrical

    
  Tubular Heater Diameter
.260"
.315"
.375"
.430"
.475"
 
  Maximum Volts
Maximum Amps per element
240
277
840
550
550
15
30
40
40
40
 
     
Resistance Tolerance:    +10%, -5%
Wattage Tolerance:    +5%, -10%
Maximum Watt Density Aluminum Alloy—35 W/in2 on the element
Maximum Watt Density Bronze or Brass—45 W/in2 on the element

Special Features
The following special features can be incorporated into Cast-In Heater designs. Specify exact dimensions and locations.
Holes, Standoffs, Cutouts, Taper Angles, Slots, Chamfers, Thermowells, Electroless Nickel Plating, Teflon® Coating, Mounting Studs, Ground Studs

 
Liquid Cooled Cast-In vs. Air Cooled Cast-In
 

Historically,liquid cooled Cast-In Heaters have been the more frequently employed method of controlling the melt temperature of extrusion barrels. There is no doubt about the effectiveness and speed of liquid cooled castings in removing heat from the extrusion process. However, there are a number of drawbacks that primarily relate to maintenance-associated issues. Air Cooled Cast-In Heaters are virtually maintenance free and therefore, when properly installed and applied, have the capability to far outlast their liquid cooled counterparts. Since cooling tubes are not used, the possibility of breakage, cracking or becoming clogged with brine or mineral deposits is not a concern.

 
Additionally, Air Cooled Cast-In Heaters do not require an expensive cooling tower or heat exchange system, extensive plumbing systems and labor for installation. These factors along with the benefit of being maintenance free make Proheat Air Cooled Cast-In Heaters an economical and practical source for your extrusion heating and cooling application.


In certain instances where air cooling alone will not sufficiently cool the process, liquid cooling tubes can be cast into the heater as well to maximize BTU removal.
 

Ordering Information




 

• Measure the O.D. of your barrel, which in turn will be the I.D. of the heater.
• Measure the width of your heater.
• Check the wattage and voltage rating per half or per segment. This information is normally stamped on the heater.
• Establish heater cooling function, if any. If water cooled, measure length and diameter of cooling tube extensions. Cooling tube extensions are 3" long, and 1/2" * .049 O.D. wall thickness unless otherwise specified. If air cooled, Cast-In Band will have cast fins.
• Check for special features such as: thermocouple clearance holes, drill and tapped holes, vent cutouts and terminal boxes.
• There are two methods for securing a Cast-In Band Heater to a barrel; separate clamping straps or nut and bolt clamping.