Cast-in aluminium and brass heating elements for plastics processing, extrusion and special applications. In-house permanent-mould and sand casting, 3D design and CNC machining.
Ihne & Tesch cast-in heating elements are used in plastics and rubber processing and in many other industries requiring uniform heat.
Ihne & Tesch cast-in heating elements suit all common applications:
Technical data, operating instructions and certificates
A cast-in heating element is worthwhile whenever standard band heaters cannot achieve full contact or the process is temperature-critical. With complex geometries, high temperatures or tight tolerances, full-surface contact provides uniform heat transfer, reducing energy losses, preventing hot spots and stabilising the process.
The most common cause is insufficient contact between the band heater and the component. Even small gaps cause heat loss and uneven temperatures. A precisely fitted cast-in heating element provides full contact and much more uniform temperature control.
Energy losses are generally caused by poorly fitting heaters and uninsulated surfaces. Cast-in heating elements with direct heat transfer and optional insulation significantly reduce lost heat, lowering energy consumption and improving process stability.
Hot spots are often caused by uneven heat distribution or an incorrect watt density. A customised heating solution with uniform contact distributes heat across the entire component in a controlled manner. Correct sensor positioning can also be decisive for stable control.
The required output depends on component geometry, mass, target temperature and process. Excessive output causes overheating and wear; insufficient output produces unstable temperatures. Each heater is therefore engineered individually for uniform, controlled heating.
Service life depends strongly on design, temperature range and operating conditions. Their solid construction and full-surface contact generally give cast-in heating elements a considerably longer life than standard band heaters. Correct engineering and installation are essential.
In many cases, conversion is both possible and beneficial. It offers clear advantages where temperature deviations, high energy consumption or short service life recur. The existing geometry is recorded and converted into a precisely fitting solution.
Exact dimensions are essential for sound engineering, including diameter, width, cut-outs, holes and connection positions. The more accurate the data, the better the fit and the more stable the subsequent process.
Thermal conductivity determines how quickly and uniformly heat spreads through the element. Aluminium provides rapid, uniform distribution, while brass is used at higher temperatures. Correct material selection is vital to heater efficiency and service life.
Once the technical data and geometry have been clarified, manufacture can normally be completed within a few weeks. In-house production also allows rapid modifications and custom solutions, which is particularly important during downtime or for urgent replacements.
