Smiths Group Acquires Osram Sylvania Process Heat and Tutco SureHeat is the New Name

This was announced by Tutco SureHeat formerly known as Osram Sylvania Process Heating Division on November 1, 2017:

Smiths Group PLC  Acquires OSRAM SYLVANIA INC’s Process Heating Division, rebrands as TUTCO SureHeat

Recently, Smiths Group PLC completed the acquisition of OSRAM SYLVANIA INC’s Process Heating Division, a New Hampshire based company globally providing a wide variety of process heating products and custom solutions to OEM manufacturers, university research departments, and industrial facilities.  The newly branded division will operate as part of TUTCO’s Heating Solutions Group and be branded as TUTCO SureHeat.  TUTCO SureHeat manufacturing facilities will remain in Exeter, NH.  This acquisition will significantly benefit the brand’s position by improving its capabilities and product portfolio.

Dane Owen, Vice President and General Manager of TUTCO in Cookeville, TN, announced the merger on November 1st, 2017.  Owen said that the merger of the two companies offers unique and highly engineered solutions with a wide assortment of applications and customers.  He continued by saying that as the two companies have begun the process of sharing information, technologies, and business practices. With this acquisition, TUTCO will become a stronger business partner and will better serve a wider range of customers.

Founded in 1938, TUTCO has quickly grown into a global leader in the heating component industry. The TUTCO Heat Solutions Group is the largest supplier of electric resistance heating elements for a broad range of applications. Through Farnam and SureHeat brands, TUTCO also provides custom heating solutions for a myriad of industrial, OEM, testing, and research applications.  As a division of Smiths Group, TUTCO has the most complete heating product catalog managed by the group’s Specialty Engineering division of Flex-Tek.

In 1968, then operating as part of OSRAM SYLVANIA, Inc., the process heat engineering team developed an innovative heating element that exceeded the industry demand for a clean, efficient, and highly controllable source of heat. The Serpentine design overcame the challenges of the manufacturing industry and ensured better heat transfers, faster and higher temperatures and longer heater element life—qualities unmatched in the industry.

Manufactured in the USA, Tutco SureHeat air heaters are used in aerospace, automotive, industrial, electronic, food, medical, packaging, plastics, pharmaceutical, printing and numerous applications throughout the world. Tutco SureHeat understands industrial facilities are dependent upon productivity, safety, and efficiency. Every component, machine, and process impacts operational cost. In today’s industrial environments, meeting productivity goals can mean the difference between success and failure. As the need for higher temperatures has increased so has productivity demands. This is a problem for most air heaters. Reaching and maintaining temperatures quickly can result in dramatically reduced heater component life.

Link to the Tutco SureHeat Announcement


Tutco Sureheat® Offers Max HT 900°c Air Heaters To Product Line


Tutco SureHeat now offers a process air heater that will allow manufacturers to increase productivity through increased speeds.  This breakthrough design provides higher process temperatures without contributing to excessive heater replacements and down time.

The Tutco Sureheat facility in New Hampshire has been producing electric process air heaters for over 40 years to provide precise/repeatable heat that can be targeted where needed. New heater designs are constantly being added to meet changing requirements in the industry. Tutco SureHeat is under new ownership and very proud of their expanding product line for higher temperatures by adding a 900°C air heater in response to industry needs. The SUREHEAT® MAX HT reduces down-time and extends heater life with a rugged element design, when it is compared to a standard heater running at a lower process temperature.

Why were the Tutco SureHeat Max HT Heaters made?

The need for higher temperatures has grown for several reasons:  increased productivity demands higher equipment speeds, which requires higher process air temperatures; new products being developed require higher processing temperatures; and many heating applications are being converted from gas flames to hot air.

Existing heaters that were being run at or near their maximum recommended temperatures could be pushed to run at slightly higher temperatures, but only with DRAMATICALLY shortened heater life.  This resulted in frequent heater replacements and increased downtime. Any increase in productivity had to be carefully balanced against the increased operating costs due to replacements.

A second option was to connect two heaters in a series, using the second heater to provide a slight boost to the temperature exiting in the first heater. This option was limited to heaters specifically designed for high inlet temperatures such as the Tutco SureHeat flanged heaters and threaded inline heaters.

The SUREHEAT® Max HT is designed to heat air to 1652°F (900°C) over a wide range of air flows, not just at one flow rate, and in a real world production environment of typical vibrations and movement. The 1652°F temperature is 252°F (140°C) HIGHER than the standard TUTCO SUREHEAT Max.

The increase in air temperature is made possible by increasing the length of the heater slightly, which allows for an increase in the surface area of the element wire.  It also provides an increase in the dwell time of the air inside the heater, while supporting the element winding over its ENTIRE LENGTH, not just on the ends of the windings.

By increasing the overall length of the heater, TUTCO SUREHEAT is able to increase the element wire length and diameter while maintaining the same wattage. The increased wire diameter makes for a more rugged element, and increasing the diameter and length provides more surface area for transferring energy from the element to the air. The increased length also increases the dwell time of the air inside the heater and allows the air temperature to more closely approach the wire temperature.

sureheat_max_ht_performanceThe key to being able to make a longer element without sacrificing heater robustness, is our serpentine winding and the supporting threaded ceramic rod. Each turn of the element winding is individually supported on the center threaded rod to eliminate the potential for the element to sag towards one end due to vibration, gravity and/or air flow pressure. Standard helical coils are supported on the ends only and tend to sag over time. Helical coil sagging issues occur more often with increased coil length. As the element turns bunch up at the exit end of the heater, the watt density and element temperatures increase, which dramatically shortens heater life.

Additional Features:
• Small size – 4” diameter body
• Threaded inlet and exit ports for convenient air connections in systems
• Built in terminal strip and high temperature plastic wiring enclosure
• Rugged stainless steel heater body
• Stainless steel mounting base
• Built in external duplex type K Exit thermocouple & Inlet type K thermocouple for low flow protection
• Exposed wire low mass element for fast heat up/cool down
• Rated for pressures up to 60 PSI (4 bar)
• UL Recognized component

Part Number Max. Watts Max. Volts Max. Amps  60 Deg C Wire Size* 90 Deg C Wire Size*
077081 18000 240 3P 43.4 8 10
077082 18000 380 3P 27.4 10 12
077083 18000 480 3P 21.7 12 12
077084 30000 380 3P 45.6 8 8
077085 36000 480 3P 43.4 8 10

* These are recommended wire sizes.  Follow applicable electrical codes during installation!!!

Tutco SureHeat offers engineering assistance in selecting the proper heater model and control system for your application. The Max HT model’s convenient electrical connections, integral thermocouples, and threaded air ports make mounting the heater quick and easy.  Call Jobco Inc. at 479-424-1300 to select the right Tutco SureHeat Max HT heater for your application.


OSRAM SYLVANIA’S  Process Heat Department manufactures all products per the plant’s document control system, which is a centralized database for total material traceability. OSRAM only uses approved drawings and checks each product per a standardized AND documented quality management system.

Within this quality system, quality check cards are created during a production run.  The quality check cards assist with inspection criteria for the finished assembly and are used to confirm the part meets the necessary electrical requirements.  The quality check cards from production runs are kept on file for one year.

The quality check cards contain the following information:  assembly operator, production date(s), drawing number with revision, part number, production quantity, resistance level measured, HYPOT test measured (if applicable), Pass/Fail results, check off verification of correct labeling and identification, and an inspector sign-off with the date.

Standard operating procedures for complicated heater or control box assemblies are created and approved by the Project Foreman.  These detailed work instructions are a step-by-step guide for the assembly operator to follow.

In addition to the quality inspection cards and the standard operating procedures, Osram’s speciality flanged inline heaters also have a testing and inspection certificate protocol that can only be completed by an approved OSRAM quality engineer.  The quality engineers perform a visual  inspection, a resistance test, and a HYPOT test.  Resistance values must correlate with the approved kilowatt rating for the particular heater model.  This certificate must be approved, signed & filed per the Osram document control system requirements. Certificate copies are provided to the customer upon completion of the speciality flanged heater order.

Hot Air Heaters & Catalyst Element Testing

Did you know that Osram Sylvania hot air heaters are used for emission testing catalyst elements by accurately simulating the high engine temperatures involved in the oxidation and reduction of nitrogen oxide and carbon monoxide into less hazardous substances like carbon dioxide?

The heaters are ideal for a laboratory environment to provide accurate hot air temperatures for testing combustible engines and components in the airline, automotive, and aerospace industries.

Tutco SureHeat (Sylvania) Air Heater Failures Due to Voltage Overshoot or Zero Airflow

Element failures caused by voltage overshoot while airflow was present.  Since the airflow was present, the damage occurred only at the air exit end. download

This element had a voltage overshoot with airflow, but not enough to keep the ENTIRE length of the heater element below 1900F.  Damage occurred at the middle and air exit ends.

Element failure caused by applying voltage when there is zero airflow.  Please note the damage occurs along the entire length of the coiled element.