If you’re in the engineering or industrial manufacturing sector, you know that long lead times can disrupt your production flow. That’s exactly what one OEM specializing in fluid conditioning equipment faced recently. They relied on immersion heaters to process used oils—like hydraulic oil and diesel fuel—but struggled with delays from their current vendor. Fortunately, they found a solution by partnering with Tempco, a leader in electric heating elements for over 50 years. Here’s how their experience can inspire your own.

Tackling Process Application Challenges Head-On

When it comes to designing a custom immersion heater, understanding the application is key. Tempco gathers detailed information about the specific process before diving into design. In this case, the OEM’s application involved a vacuum dehydration oil purification system. This system transforms used oils into usable products by removing water, particulates, and gases through heat and filtration.

One unique aspect of this setup is its portable skid, which allows for easy movement between different machinery within manufacturing facilities. This portability means the immersion heater must accommodate varying factors like watt density (ranging from 7 to 12 watts per square inch), burn temperatures, and oil weights.

Choosing the Right Immersion Heater for Your Needs

Once we gather all the necessary application details, we define the type of heater required. For the OEM, the top priorities were clear:

1. An immersion heater that heats liquids directly.
2. A tubular heating element that is both versatile and customizable.
3. A mounting flange for easy integration with their equipment.
4. Lightweight aluminum fins that are effective for low-watt density heating.

Tempco’s extensive product lines allow for a wide range of custom and stock elements, but in this instance, we realized that our existing offerings didn’t meet the specific needs of the OEM.

Dedicated Customer Service for Tailored Solutions

Tempco pivoted to address the OEM’s unique needs. With our established manufacturing processes, our engineers quickly got to work designing a brand-new product line. Thanks to our efficient manufacturing processes, we could also promise faster delivery times. 
  
Introducing the Tempco Aluminum Finned Flanged Immersion Heater (FAH)
The result? A custom-designed flanged immersion heater that perfectly aligned with the customer’s requirements. Here are some key benefits of this innovative product:

• Low-Watt Density Surface: This feature allows for shorter element lengths, making it more efficient. 
• Aluminum Fins: These fins provide smooth, uniform heat transfer to the oil, ensuring consistent performance.
• NEMA Rated Electrical Termination Housing: This adds an extra layer of safety and reliability.

Benefits for All OEMs in Oil Filtration Systems

While the specific solution was tailored for one OEM, the benefits of this new immersion heater extend to all manufacturers working with oil filtration systems. Tempco established standard design features based on collaboration, making these heaters ideal for:

• Immersion heating of oils
• Heating hydraulic fluids 
• Processing organic fluids that are non-corrosive to aluminum

The lightweight aluminum fins not only enhance thermal conductivity but also improve the overall efficiency of the heating process compared to traditional materials like stainless steel.

Additional Features Designed for OEMs
Tempco also offers a variety of optional features to meet diverse needs:

• Electrical Variations: Choose from single- or three-phase wiring options.
• Internal Temperature Sensors: Keep track of heater performance in real-time.
• Customizable Flange Sizes: Adapt the heater to fit various application requirements.

Long-Term Partnerships with Tempco

The collaboration between the OEM and Tempco didn’t just result in a single product; it established a long-term partnership. By working closely together, we ensured that all heating requirements were met. The OEM was pleased with both the new immersion heater and the significantly improved delivery timeline.
Today, they continue to rely on Tempco for their immersion heater needs, and you can too. Our expertise, attention to detail, and commitment to customer satisfaction make us the perfect electric heater supplier for OEMs like you.

So, if you’re facing similar challenges with long lead times or need a custom process heater, don’t hesitate to reach out. Let Tempco help you streamline your operations and meet your heating requirements efficiently. Contact us today with your application details, and let’s work together to find the perfect solution for your business!