CAST HEATER/CAST-IN-HEATER

Industrial applications

APPCLICATIONS

Cast Heaters are used within polymer and rubber processing industries (extrusion). Furthermore they are suitable for screen-changers and filter systems, for extrusion tools, for foiling and blow moulding machinery, for profile welding machinery, for slot dies (e.g. plate and foil extruderds), for sealing-, packaging and dairy machinery, for accumulator grid moulding, as pre-heating station for forging tools, as special application (e.g. within the laboratory sector) or as chiller.

Options

protection types as per protection classification up to IP67
EX-protection with ATEX-certificate
Heat-Cool-Combination with additional cooling jacket or integrated (cast-in) cooling tube
with additional insulation

up to 450°C
operating temperature aluminium
up to 650°C
operating temperature brass
up to IP 67
protection

Cast-In Heaters

Cast-in Heaters
Shape examples

example 1
Cast-In Heaters
flat heater
e.g. for slot dies
Cast-In Heaters
example 2
cast-in cylinder heater
e.g. assembly on screen changers; extrusion
Cast-In Heaters
example 3
cast-in angular heater
e.g. for tool heating
Cast-In Heaters
example 4
cast-in heater
e.g. for tubes and tube bows
Cast-In Heaters
example 5
cast-in heater
e.g. for ball taps or valves
Cast-In Heaters
example 6
cast-in heater
e.g. for strand drying

cast material	term	density	heat transfer capacity	operating temperature¹	surface load²
AlSi8Cu3 aluminium	AL	2,7 kg/dm³	110 - 130 W/(m • K)	≤ 450 °C	4 W/cm²
AlSi7Mg0,3 aluminium	AL	2,6 kg/dm³	160 - 170 W/(m • K)	≤ 450 °C	4 W/cm²
CuZn39Pb brass	MS	8,5 kg/dm³	65 - 85 W/(m • K)	≤ 650 °C	6 W/cm²

¹ without coating, measured on the Surface of the heater
² recommended

Connection examples

Cast-In Heaters
example 1
aluminium standard casing/perforated tube, IP54/IP65
Cast-In Heaters
example 2
aluminium standard casing/flat tube, IP54/65
Cast-In Heaters
example 3
EX-protection, IP67
Cast-In Heaters
example 4
stainless steel connection casing, IP65
Cast-In Heaters
example 5
contact fitting, IP20
Cast-In Heaters
example 6
cast on cap, IP54
Cast-In Heaters
example 7
connection tube with leads, IP30
Cast-In Heaters
example 8
countersink connection, IP20
Cast-In Heaters
example 9
direct exit, IP00

Clamp and fastening examples

example 1
screwed on
Cast-in Heaters
example 2
Tone-sided disc-springs, clamp band
Cast-In Heaters
example 3
both-sides disc-springs, cast on tensioning bracket
Cast-In Heaters
example 4
one-sided springs, hingeable
Cast-In Heaters
example 5
direct screwed with clamp band
Cast-In Heaters
example 6
disc-spring lock, cast on clamping strap

Options

protection types as per protection classification up to IP67
EX-protection with ATEX-Certificate
with additional cooling jacket and blower connection flange
with additonal insulation
various coatings e.g. nonstick coating, chemical galvanized, others on request
parallel surfaces
milled out slots with grounded surfaces
temperature control through to integral thermo sensors, please take a look at our data sheet for temperature sensors
various shapes and machining on own chill-/ sandcasting and modern CNC centres
production, reconditioning, repair and maintenance of Cast Heaters for packaging industry

Technical Data
moulded in Tubular Heaters	stainless steel 1.4541 or 1.4828, Ø 6.5 mm or Ø 8.5 mm or Ø 10 mm, others on request
moulded in cooling tubes	stainless steel 1.4512 Ø 12x1, others on request
operating voltage	230V, 230/400V and 400V, others on request
performance	on customer request and technical possibility tolerance ±10 % (±5 % on request)
unmachined gravity cast quality	lasting mould: Ra 3,2 - 50 sand cast: Ra 12,5 - 50
machined surface quality	drilling: Ra 0,8 - 12,5 milling: Ra 1,6 - 12,5 grinding: Ra 0,2 - 0,8
wall thickness	Tubular heater Ø 6,5 mm: standard 15 mm (min. 11 mm) Tubular heater Ø 8,5 mm: standard 25 mm (min. 15 mm)
high voltage stability	as per EN 60204
insulation resistance	as per EN 60204