Let’s Build the Right Heating Solution
1535 Burgundy Parkway, Streamwood, IL 60107, USA
Introduction
AKINSUN Ceramic Redband® Heaters are engineered for industrial processing applications where rapid, efficient heating directly contributes to productivity. These ceramic band heaters are capable of generating the higher temperatures required for processing today’s high-temperature resins.
Due to the low thermal conductivity of the ceramic fiber insulation, the external surface temperature of the heater remains approximately 400°F (204°C) while the internal surface temperature can reach up to 1200°F (650°C). This design maximizes heat delivery to the process while reducing heat loss to the surrounding environment.
Ceramic band heaters are manufactured in a full range of standard construction variations, physical dimensions, electrical ratings, and terminal or lead termination configurations. They are flexible, easy to install, and designed with interlocking ceramic bodies that allow the heater to be opened and wrapped around the cylinder. AKINSUN heaters are built using high-quality materials to ensure long service life and dependable performance.
Ceramic band heaters can also be custom manufactured to meet specific size, diameter, wattage, and termination requirements.
Features
Terminal Box
A heavy-duty steel terminal box provides excellent protection for exposed terminals. The enclosure includes a 5/8″ knockout compatible with standard conduit or flexible armored cable connectors.
Screw Terminals
Screw terminals are standard on most ceramic insulated band heaters. Stainless steel screw terminals are connected to solid nickel pins, providing maximum amperage-carrying capacity. Terminal brackets are positioned 180° opposite the screw terminals for balanced electrical and mechanical performance.
Stainless Steel Sheath
The stainless steel housing features serrated edges for maximum flexibility and ease of installation. The sheath wall thickness is selected to deliver optimal mechanical strength and thermal conductivity, and it will not become brittle under high-temperature operating conditions.
Ceramic Fiber Insulation
A 1/4″ thick ceramic fiber insulation is used for its excellent dielectric properties and thermal efficiency. This insulation keeps heat concentrated on the cylinder rather than dissipating into the atmosphere. Specially designed mounting brackets with 1/4″-20 socket cap screws evenly and securely draw the heater assembly against the cylinder across its full width.
Nickel-Chromium Resistance Wire
Resistance wire is selected in multiple sizes and resistance values, then precision-wound using automated equipment. This allows the maximum amount of resistance wire to be incorporated into each heater, enabling high heat output while maintaining lower operating temperatures within the element.
Radial Lockup Flange
A heavy-duty stainless steel radial lockup flange is spot-welded to the outer sheath. It applies uniform pressure across the width of the band, ensuring a secure fit and consistent heat transfer.
Ceramic Insulated Band Heaters – Application Overview
Plastic processing applications require high operating temperatures and fast production cycles. AKINSUN ceramic band heaters are designed to meet these demands and function as high-temperature electric furnaces, delivering efficient heat transfer through conduction, convection, and radiation. Integrated insulation minimizes unwanted temperature variations along the barrel.
Unlike conventional conductive band heaters, which require an intimate fit with the heated surface, ceramic band heaters maintain efficient heat transfer even on irregular or grooved surfaces. Surface irregularities that would normally create air gaps, hot spots, and premature heater failure do not adversely affect ceramic band performance.
At higher watt densities, ceramic band heaters can be installed in wider increments than other heater types. This reduces the number of heaters required and simplifies wiring, resulting in improved system reliability and reduced installation complexity.
Ceramic Band Heater Specifications
| Specification | Value |
|---|---|
| Maximum Temperature | 1400°F |
| Nominal Watt Density | 20–45 W/in² |
| Maximum Watt Density | 45 W/in², Air Cooled: 50 W/in² |
| Maximum Voltage | 480V (Single or Three Phase) on Screw Terminals |
| Maximum Voltage (With Leads) | 240 VAC |
| Maximum Amperage | Lead Wire Termination: 10 Amp (per circuit) |
| Maximum Amperage (Screw Termination) | 25 Amp |
| Resistance Tolerance | +10%, −5% |
| Wattage Tolerance | +5%, −10% |
| Insulation (Ceramic Fiber Blanket) | Standard Thickness: 1/2″Double Thickness: 1″ |
| Terminals | 1/4-20 Post Terminals (Standard) |
| Sheath Material | Stainless Steel |
| Lockup | Flange Type (Standard) |
| Minimum ID – One Piece | 2″ |
| Minimum ID – Two Piece | 4″ |
| Maximum ID | 25½” (2-Piece Construction)15″ (1-Piece Construction) |
| Standard Width Increment | 1/2″ |
| Standard Gap When Tightened | 1/4″ |
| Thickness with 1/2″ Insulation | 5/8″ |
| Thickness with 1″ Insulation | 7/8″ |