When it comes to versatility, infrared (IR) heating operates on a wavelength that people never see but experience daily. Those hot dogs rotating at the convenience store, the warm plates at restaurant pass-through windows, and the sauna you relax in may all rely on infrared technology working behind the scenes.

The science behind this invisible energy transfer has revolutionized manufacturing processes across industries, from precision plastic thermoforming to commercial food service operations. Infrared heating operates through electromagnetic radiation, transferring energy directly to objects.

This fundamental difference from convection heating creates significant advantages in industrial applications where precision, speed and energy efficiency matter most. Tempco helps customers harness them for a wide variety of machines and appliances.

 "The biggest advantage for Tempco is we're very custom," said Neal Kosak, a design engineer who specializes in infrared applications. "Even though certain IR supplies we make are very standardized, we are very open to working with customers to develop the components they need. We are very flexible.”

Plastics Industry Applications: Precision Heat for Complex Processes

The plastics industry has embraced infrared heating technology for its ability to deliver precise, controllable heat directly to polymer surfaces. Unlike convection heating that warms surrounding air, infrared energy penetrates plastic materials and heats them from within, creating a uniform temperature distribution essential for quality manufacturing.

Thermoforming processes rely on infrared heating to raise the temperature of plastic sheets to their forming range—typically between 280°F and 320°F for polystyrene and 340°F and 380°F for ABS plastics. IR heaters positioned above and below the plastic sheet provide controlled heating zones, ensuring a uniform temperature distribution across the entire forming area.

"You can heat a piece of material and it will get malleable. Then you can form it over something else, like a mold," Kosak explained, describing the fundamental principle that makes infrared heating so effective for plastic processing applications.

Tempco's ceramic emitters operating in the 2.5-6 micrometer range prove particularly effective for thermoforming applications. The rapid response characteristics of infrared heating allow for precise temperature control during the critical heating phase.

Advanced Plastic Processing Applications

Beyond basic thermoforming, infrared heating enables sophisticated plastic processing techniques that showcase the technology's precision. Plastic welding operations utilize focused IR energy to soften material edges at temperatures between 400-500°F, creating molecular bonds stronger than adhesive joints. Precise heat control prevents material degradation while ensuring complete fusion.

Composite curing processes benefit from IR heating's ability to maintain consistent temperatures across complex geometries. Carbon fiber-reinforced plastics require precise temperature profiles—typically 250-350°F for epoxy systems—that infrared heaters can maintain throughout the entire curing cycle.

IR heating proves effective for drying plastic coatings and inks, where no fans or contact is required. This approach ensures a drying process that won't smudge paints or damage the material, making it suitable for high-speed production lines.

Surface preparation and coating applications utilize infrared energy to activate adhesives and cure protective coatings, eliminating the need to subject the entire part to elevated temperatures. This selective heating approach prevents warping in thin-walled components while ensuring complete polymerization of the coating.

Food Service Applications: Safety, Efficiency, and Quality

Commercial food service operations rely on infrared heating for both food preparation and holding applications, where temperature control, energy efficiency, and food safety intersect. IR technology addresses unique challenges in professional kitchens while meeting strict health department requirements.

Unlike traditional heat lamps that create hot spots and uneven heating, properly designed IR systems distribute heat uniformly across serving areas.
The dry heat characteristic of infrared energy prevents condensation that can compromise food texture and appearance. French fries stay crispy, pizza crusts maintain their texture and proteins retain their surface characteristics during extended holding periods.

Commercial buffet applications particularly benefit from IR heating's ability to maintain consistent temperatures across large serving areas. Multiple heating zones allow operators to customize temperatures for different food types—proteins at 165°F, vegetables at 140°F and sauces at 180°F—all within the same serving line.

Rapid Cooking and Finishing Operations

High-intensity infrared heaters enable rapid surface heating for finishing operations that would be impossible with conventional methods. Pizza ovens incorporating IR elements can achieve surface temperatures exceeding 800°F in seconds, creating the high-heat searing that produces restaurant-quality crusts.

Kosak and his team were recently contacted by a customer interested in incorporating IR heating in a brownie machine. With IR arrays positioned on the bottom, the trays above would remain at a steady temperature, ensuring the treats stayed soft and warm and wouldn’t stick to the surface.

Food Safety and Sanitation Benefits

The dry heat environment created by infrared heating systems naturally inhibits bacterial growth, an important consideration in commercial food service operations. Surface temperatures above 160°F effectively eliminate common foodborne pathogens, while the absence of moisture prevents bacterial growth and multiplication.

Additionally, IR heating systems generate no air movement, preventing cross-contamination between food items and reducing airborne particulate contamination that can occur with forced-air systems.

Custom Solutions: Engineering Excellence

Tempco's approach to custom infrared heating solutions demonstrates how engineering expertise can solve unique thermal challenges across industries. The company's in-house capabilities include pattern shops, CNC machining centers and specialized foundry operations that enable complete custom heater manufacturing.

When Hoffman Design Works approached Tempco for help simulating spacecraft re-entry conditions, the challenge required heating a large titanium sheet to 1,000°F.  The solution involved an array of short-wave halogen lamps that were able to complete this feat in less than a minute.

A leading automotive supplier once required a secondary drying operation for fabric coatings. Tempco developed an innovative custom assembly featuring KTE E-Mitters mounted in a highly reflective aluminum-steel housing.

Looking Forward: Infrared Heating Innovation

The versatility of infrared heating technology continues to expand into new applications as engineers better understand the characteristics of electromagnetic radiation and develop more sophisticated control systems.

The combination of energy efficiency, process control and environmental benefits positions infrared heating as a key technology for manufacturers seeking competitive advantages through thermal process optimization.
Whether your application involves plastics processing, food service operations or specialized industrial heating requirements, infrared technology offers proven solutions backed by decades of engineering expertise and continuous innovation.