Why are thermal insulation jackets useful in injection moulding and extrusion?

Injection moulding machines and extruders lose some generated heat from the barrel surface. Thermal insulation jackets reduce this loss and keep heat in the process, lowering energy consumption, stabilising temperatures, reducing radiant heat and improving the working environment.

Can thermal insulation jackets be retrofitted to existing machines?

Yes. Thermal insulation jackets can often be retrofitted to existing injection moulding machines, extruders, presses or tool heaters. Photographs, drawings, barrel dimensions, diameters, lengths, connection positions, temperature range and machine details are useful for an enquiry.

What benefits do thermal insulation jackets offer besides energy savings?

Besides reducing energy consumption, thermal insulation jackets can improve working conditions, reduce radiant heat and hot surfaces, lower the ambient temperature around the machine and support temperature stability.

Thermal Insulation Jackets for Industrial Heating Processes

Q: Which outer coatings are available?

Thermal insulation jackets are normally made with technical fabric. PTFE-coated and aluminium-faced surfaces are available as options. PTFE can assist chemical resistance and cleaning, while aluminium supports heat reflection.

Technical expertise

Technical reference for industrial thermal insulation

Ihne & Tesch treats thermal insulation jackets not as standard accessories but as engineered components within an industrial heating process. The decisive factors are energy efficiency, workplace safety, service-friendly installation and a precise fit for the actual installation conditions.

Energy Reduce heat losses

Reduces unused heat radiation during continuous operation and quantifies the potential savings.

Safety Reduce surface temperatures

Reduces hot external surfaces and improves workplace safety around machines and heating zones.

Engineering Engineered for a precise fit

Cut-outs, connections, sensors, geometries and fastenings are matched to the actual installation conditions.

System Consider the complete heating process

The insulation is considered together with the heating element, sensors, controls and machine.

At a glance

Product Thermal insulation jackets Insulation and thermal protection

Max. temperature 500 °C

Thickness approx. 20 mm Standard

Min. width/length from 30 mm

Energy saving up to 40% application-dependent

Manufacture Custom-made made to measure

Delivery time 2–3 weeks Custom manufacture

Benefits

Why industrial thermal insulation delivers multiple benefits

Energy

Less heat loss

Insulated heating zones release less unused heat into the surroundings, reducing energy demand during continuous operation.

Safety

Lower surface temperatures

Thermal insulation jackets reduce hot external surfaces and improve protection against accidental contact around the machine.

Process

More stable temperature control

Reduced exposure to draughts and environmental influences supports repeatable processes at barrels, tools and heating zones.

Retrofit

Optimise existing systems

The design is adapted to existing machines, connections, sensors and maintenance access points.

Working environment

Improved production environment

Lower heat radiation reduces thermal stress at workstations, on peripheral equipment and in the production hall.

CO₂

Make efficiency measurable

The calculator makes potential savings transparent and provides a technical basis for an enquiry.

Applications

For machines, barrels and complex heating zones

Thermal insulation jackets are used where heat is critical to the process and uninsulated surfaces adversely affect energy consumption, safety or process stability.

Barrel insulation Extruders Injection moulding machines Flat heaters Tool heating Insulation covers Insert insulation Heating zones with cut-outs Nozzles and barrel heads Special-purpose machinery

Engineering process

Step 1MeasurementsGeometry, temperature and operation

Step 2CalculationAssess potential savings

Step 3DesignCut-outs and fastenings

Step 4Manufacturecustom-made to measure

Custom design

Manufactured to fit your installation precisely

Standard insulation is interchangeable. Engineered thermal insulation takes account of geometry, sensors, connections, maintenance access and the installation sequence.

custom geometries holes and apertures cut-outs for sensors cut-outs for connections spring/ring fastening tensioning/strap fastening hook-and-loop fastening press studs hot-surface warning label identification marking special materials on request alternative thicknesses on request PTFE-coated aluminium-faced

Gallery

Application images and fastening options

The gallery shows actual Ihne & Tesch designs: thermal insulation jackets with different coatings, fastenings, cut-outs and applications on heated components.

Thermal insulation jacket for heated industrial components — **Custom thermal insulation jackets** Custom insulation for heating zones, barrels, tools and bespoke geometries.

Thermal insulation jacket with spring and ring fastening — **spring/ring fastening** Rapid installation where repeated maintenance access is required.

Thermal insulation jacket with tensioning and strap fastening — **tensioning/strap fastening** Robust fastening on cylindrical and complex components.

Thermal insulation jacket with hook-and-loop fastening — **hook-and-loop fastening** Service-friendly, flexible and quick to remove.

Detailed view of a thermal insulation jacket with cut-outs — **Cut-outs and apertures** Designed for sensors, connections and maintenance access.

Band heaters before fitting thermal insulation jackets — **Before: exposed band heaters** Uninsulated heating zones release heat directly into the surroundings.

Band heater with a fitted thermal insulation jacket — **After: insulated heating zone** Thermal insulation jackets reduce radiant heat and improve protection against accidental contact.

Technical features

Compact technical overview

Feature	Specification	Benefits
Temperature range	up to 500 °C	for industrial heating zones and plastics processing
Standard thickness	approx. 20 mm	compact insulation with service-friendly installation
Minimum size	from 30 mm width/length	also suitable for smaller heating zones and bespoke geometries
Outer coating	standard fabric, PTFE-coated or aluminium-faced	matched to the environment, cleaning requirements and heat reflection
Fastenings	spring/ring, tensioning/strap, hook-and-loop or press stud	matched to installation, maintenance and the existing system
Options	warning label, custom identification, alternative materials and thicknesses on request	technical adaptation to the machine, operator standards and operating environment
Manufacture	custom-made to measure	cut-outs, apertures and OEM versions available

Factor	Lower saving	Higher saving
Process temperature	Low (below 200 °C)	High (above 300 °C)
Ambient temperature	Warm hall, little draught	Cold hall, open doors
Band-heater surface	Small, minimally exposed	Large, freely exposed
Operating hours per year	Single-shift operation	Three-shift operation, 24/7
Electricity price	Low (below 15 ct/kWh)	High (above 25 ct/kWh)

Savings calculator

What insulation can save you.

Select your band-heater type and enter its dimensions. The calculation updates immediately.

Band-heater type

Z Micamax. 3,5 W/cm² ZAK Compact aluminiummax. 4,5 W/cm² M Micanitemax. 5,0 W/cm² MC Compact micanitemax. 6,0 W/cm² KHK Ceramicmax. 6,5 W/cm²

Band-heater dimensions

Diameter

Width / length

Surface area: 565 cm² · Output: 2.5 kW

Number of band heaters

Operating days per year

240

Electricity price (cents/kWh)

20 ct

Total output 17.8 kW

Total surface area 3,958 cm²

Energy cost without insulation

€10,656

Energy cost with insulation

€7,459

Your annual saving

€3,197

Saving per day € 13

Payback period approx. 6 months

CO₂ per year ~ 3.8 t

Request a quotation for your machine →

Indicative values based on your entries (radiant loss approx. 37% of heater output, insulation saving approx. 30%, 16 hours of operation per day). Actual savings depend on the process and system; we will gladly calculate your specific scenario. CO₂ calculation uses 0.18 kg CO₂/kWh as an indicative Austrian electricity-mix value.

FAQ

Frequently asked questions

Ihne & Tesch thermal insulation jackets can significantly reduce energy consumption on heated barrels, tools and machine components. Savings of up to 40% are possible in suitable applications.

Actual savings depend on operating temperature, machine running time, barrel size, ambient temperature, air movement, the condition of the existing heaters and insulation quality. Retrofitted insulation can pay back particularly quickly on injection moulding machines, extruders and continuously heated systems.

Thermal insulation jackets are suitable for injection moulding machines, extruders, plastics presses, blown-film systems, tool heaters, barrels, adapters, nozzle areas and other heated components in plastics processing.

The jackets are custom-made from a drawing, sketch, photograph or machine dimensions. They can therefore accommodate different diameters, lengths, contours, cut-outs, connection positions and machine geometries. Typical applications include injection moulding, extrusion, blow moulding, tool temperature control and energy-intensive processes with continuously heated surfaces.

Injection moulding machines and extruders lose some of their generated heat from the barrel surface to the surroundings. Thermal insulation jackets reduce this loss and keep heat where it is needed: in the process.

Benefits can include lower energy consumption, more stable temperature control, less heat radiation, lower surface temperatures, an improved working environment and a reduced load on production-area cooling. These effects are particularly relevant at high temperatures and with long machine running times.

Depending on the application, Ihne & Tesch offers spring/ring fastenings, tensioning or strap fastenings and hook-and-loop fastenings.

The appropriate fastening depends on installation conditions, accessibility, temperature, machine geometry and removal frequency. If jackets are regularly removed for maintenance, cleaning or tool changes, the fastening should be robust and easy to operate.

Thermal insulation jackets are normally made with a technical fabric. PTFE-coated and aluminium-faced surfaces are available as options.

PTFE-coated surfaces can be useful where chemical resistance, easier cleaning or particular process conditions are required. Aluminium-faced surfaces also reflect heat and can benefit applications with increased radiant heat. Selection should always match the temperature, environment and mechanical load.

They are secured using the selected fastening or press studs fitted directly to a band heater or tool heater. Integrated press studs can be provided on Ihne & Tesch FAK and FMK tool heaters.

The jackets must remain secure during operation while remaining accessible for maintenance or replacement. The fastening is therefore designed for the machine, geometry and subsequent handling.

Yes. Thermal insulation jackets can often be retrofitted to existing injection moulding machines, extruders, presses or tool heaters. The areas to be insulated are measured and the jackets are manufactured individually.

Photographs, drawings, barrel dimensions, diameters, lengths, connection positions, temperature range and machine details are useful for an enquiry. The more accurately the installation is described, the better the jacket can be adapted.

A technical enquiry should include the machine type, area to be insulated, diameter, length, operating temperature, existing band or tool heaters, cut-outs, connection positions, preferred fastening, quantity and, where available, photographs or drawings.

For injection moulding machines and extruders, barrel zones, nozzle areas, adapters and interfering contours are also relevant. This information enables Ihne & Tesch to assess the most suitable technical design.

Besides reducing energy consumption, thermal insulation jackets often improve working conditions. They reduce heat radiation and hot surface areas and can lower the ambient temperature around the machine.

Improved insulation can also support temperature stability because less heat is released uncontrollably into the surroundings. This is particularly beneficial in injection moulding, extrusion and continuously heated tools.

Thermalinsulation jacketsfor heating processes

Technical reference for industrial thermal insulation