What Is a Tubular Heater?

A tubular heater is an electrical resistance heating element enclosed inside a metallic tube.
The internal resistance wire converts electrical energy into heat. It is electrically insulated from the external metal sheath by a high-temperature insulating material, typically compacted magnesium oxide (MgO).
The metal sheath transfers the generated heat to the surrounding air, liquid, metal surface, or other medium being heated.
This construction provides an effective combination of:

• • Electrical insulation
• • Efficient heat transfer
• • Mechanical strength
• • Compact dimensions
• • High-temperature capability
• • Reliable industrial operation
• • Flexible heater design

Tubular heaters can be manufactured in different diameters, lengths, shapes, wattages, voltages, and sheath materials according to the intended application.

Applications of Tubular Heaters

Industrial tubular heaters are used in numerous machines and heating systems.
Typical applications include:

• • Plastic processing machinery
• • Plastic extrusion equipment
• • Packaging machinery
• • Industrial ovens
• • Industrial dryers
• • Heating tanks
• • Air heating systems
• • Duct heating
• • Mold heating
• • Die heating
• • Sealing machinery
• • Food processing equipment
• • Industrial washing equipment
• • Water heating systems
• • Oil heating applications
• • Machinery and equipment heating
• • Metal surface heating
• • General industrial heating systems

Because tubular heating elements can be produced in different shapes and configurations, they can be adapted to many different industrial heating requirements.

Construction of Tubular Heating Elements

A typical electric tubular heating element consists of a resistance wire positioned inside a metallic sheath.
The resistance wire is electrically insulated from the outer tube using high-temperature insulating material. Magnesium oxide (MgO) is commonly used because of its electrical insulation and thermal conductivity characteristics.
The basic construction consists of:

• • Electrical resistance wire
• • High-temperature electrical insulation
• • Compacted magnesium oxide
• • Metal outer sheath
• • Electrical terminals
• • Connection cables or terminal pins

The electrical resistance generates heat when voltage is applied. This heat passes through the insulation material and metal sheath before being transferred to the application.

Stainless Steel Tubular Heaters

Stainless steel tubular heaters are widely used in industrial applications because they provide a practical combination of mechanical durability, temperature resistance, and corrosion resistance.
Depending on the operating environment, different stainless steel grades or other suitable sheath materials can be selected.
Stainless steel tubular heating elements can be used for heating:

• • Air
• • Water
• • Liquids
• • Metal surfaces
• • Molds
• • Dies
• • Tanks
• • Machinery components

The correct sheath material should always be selected according to operating temperature, heated medium, environmental conditions, and application requirements.

Tubular Heaters for Plastic Processing Machinery

Tubular heating elements are commonly used throughout the plastic processing and packaging industries.
They can provide localized or indirect heating for different machine components and production processes.
Typical plastic machinery applications include:

• • Extrusion machinery
• • Plastic bag making machines
• • Packaging machines
• • Sealing systems
• • Plastic recycling machinery
• • Molds and dies
• • Heating plates
• • Cutting and sealing equipment
• • Auxiliary plastic processing equipment

Properly selected tubular heaters provide controlled and reliable heating for continuous industrial production.

Air Heating Tubular Elements

Tubular heaters for air heating can be installed in ducts, ovens, dryers, cabinets, and other systems where electrical energy is used to increase air temperature.
Depending on the application, tubular heating elements can be formed into different shapes to increase the effective heating surface and fit the available installation space.
For air heating applications, heater watt density and airflow conditions are important parameters when determining the appropriate heater design.

Tubular Heaters for Liquid Heating

Tubular heating elements can also be designed for heating liquids such as water and other industrial fluids.
Depending on the application, tubular heaters may be incorporated into immersion heater assemblies, tanks, vessels, and industrial process equipment.
The heater sheath material and watt density should be carefully selected according to the liquid being heated.
Factors such as operating temperature, corrosion characteristics, liquid circulation, heater position, and required heating capacity should be considered when selecting a tubular heating element for liquid heating.

Custom-Shaped Tubular Heaters

One of the major advantages of tubular heating elements is their design flexibility.
Tubular heaters can be formed into different geometries according to the available installation space and required heat distribution.
Depending on the technical requirements, custom heaters can be produced in configurations such as:

• • Straight tubular heaters
• • U-shaped tubular heaters
• • M-shaped heaters
• • W-shaped heaters
• • Circular heating elements
• • Spiral configurations
• • Multi-bend tubular heaters
• • Special custom geometries

Customers can provide a technical drawing, dimensional sketch, sample, or photographs for custom manufacturing.

Custom Tubular Heating Elements

Eles Machinery supplies custom-made tubular heaters according to the technical requirements of industrial machinery and heating systems.
Custom specifications may include:

• • Tube diameter
• • Overall heater length
• • Heated length
• • Cold zone length
• • Heater shape
• • Voltage
• • Wattage
• • Watt density
• • Sheath material
• • Terminal type
• • Cable type
• • Cable length
• • Connection position
• • Mounting components
• • Special bending geometry

This allows the heating element to be optimized for the machine and application rather than requiring the machine design to accommodate a standard heater.

Replacement Tubular Heaters

Tubular heaters operating continuously in industrial equipment may eventually require replacement because of electrical failure, mechanical damage, excessive operating temperature, contamination, corrosion, or insulation deterioration.
Eles Machinery can supply replacement tubular heating elements according to an existing heater sample or technical specifications.
For replacement heater inquiries, customers should provide as much information as possible, including:
Tube Diameter × Length – Shape – Voltage – Wattage – Sheath Material – Connection Type
If complete specifications are unavailable, customers can also send photographs, drawings, existing heater markings, or a physical sample.

Selecting the Correct Tubular Heater

Choosing the correct tubular heating element requires more than simply determining the voltage and wattage.
Important parameters include:

• • Required heating power
• • Operating voltage
• • Maximum operating temperature
• • Heated medium
• • Heater dimensions
• • Available installation space
• • Watt density
• • Sheath material
• • Required heater shape
• • Electrical connection
• • Environmental conditions
• • Heat transfer characteristics

Correct specification helps improve heater performance, temperature stability, and operating life.

Advantages of Tubular Heaters

Tubular heating elements offer several advantages for industrial heating applications:

• • Versatile industrial heating solution
• • Compact construction
• • Efficient heat transfer
• • High mechanical strength
• • Different sheath material options
• • Custom shapes and dimensions
• • Different voltage and wattage options
• • Suitable for air, liquid, and surface heating
• • Easy integration into industrial machinery
• • Custom electrical connections
• • Reliable replacement heater solution

Why Choose Eles Machinery?

Eles Machinery supplies machinery components, spare parts, and technical solutions for the plastic processing, plastic film, plastic bag manufacturing, packaging, and related industries.
Our tubular heating elements can be supplied according to specific machine dimensions and operating requirements.
We can assist customers looking for:

• • Industrial tubular heaters
• • Electric tubular heating elements
• • Stainless steel tubular heaters
• • Custom tubular heaters
• • Air heating elements
• • Liquid heating elements
• • Mold and die heaters
• • Replacement tubular heating elements
• • Heating elements for plastic machinery

Request a Quotation for Custom Tubular Heaters

Looking for a Tubular Heater or Tubular Heating Element for your industrial machinery?
Please send us the following information:
Tube Diameter
Overall Length
Heated Length
Required Shape
Voltage (V)
Power (W)
Sheath Material, if specified
Operating Temperature
Heated Medium – Air, Liquid or Metal Surface
Terminal / Cable Connection Type
Required Quantity
You can also send us a technical drawing, dimensional sketch, photographs, or a sample of your existing tubular heater.
Contact Eles Machinery for custom tubular heaters, stainless steel tubular heating elements, replacement heaters, and industrial electric heating solutions.