Signs Your Immersion Heater Needs to be Replaced

One way to lower equipment costs for businesses is to make sure that each piece of equipment functions to its full potential. When it comes to heating elements this can be quite a challenge. Such equipment does indeed have a limited life. However, when an immersion heater fails it is not always due to age. There are other factors that can lead to failure. 

Common Element Failures

Elements that are poorly maintained will eventually create poor heat transfer and inevitably fail after a period of time. However, before replacing, check the heater and the system to make sure it is not simply a buildup of sludge or sediment causing the issue. Sometimes the fix can be as easy as cleaning away debris from the element. Here, we outline some of the most common reasons why this happens and how to know when replacement is necessary.

Missing thermal protector: This could be caused by the protector being removed during installation or prior to servicing. WARNING: Do not operate heaters without thermal protection. 

No power/electrical fusing: This is often caused by the main disconnect being in an off position; open protector(s) or defective circuit breaker on main; loose or disconnected wiring. 

Thermostat not turning heater on (new installations): This will occur when the thermal protector is not connected to terminal blocks in control.

Heater blowing electrical protectors: The protector size must be consistent with the rating information stamped on heater nameplate/installation tag. 

Repair or Replace?

The main consideration businesses must make when deciding whether to repair or replace an immersion heater is the costs and benefits of repair vs. replacement. Depending on the situation you can either repair or replace the heater. If the damage is severe then replacement might be the better option. A second thing to consider is the value. It is not always viable to constantly repair an older unit even if it is possible. A newer immersion heater will simply give you greater value and last longer than your present unit which has probably seen better days. 

In the final analysis, no heating element lasts forever. However, when certain precautions are taken your immersion heater can have a life that is as long as any other vital equipment you own. Moreover, our custom cartridge heaters are also made to fit the needs of all kinds of businesses. Check out our models and the specs and you will see how they can be an asset to your company. 

Tips for Handling (and Preventing) Hot Weather Equipment Failure

According to the National Institute for Occupational Safety and Health (NIOSH), heat stroke is the most serious heat-related disorder and occurs when the body can no longer control its temperature. However, as a business owner you know that there is also the danger that valuable machines will overheat in the summer as well. Our coil heaters, band heaters, ring heater, hot air heater etc are products that can help businesses stay productive and avoid the loss of time and money during the heat of summer. However, part of protecting valuable equipment from extreme weather lies with you. In this article, we’ll list some tips for keeping your equipment up and running during the heat of summer.

Protect equipment from temperature extremes: Are your machines in the direct sunlight? Are they in an un-air-conditioned part of your factory? If the answer to these questions is “yes” they you may be headed for a heat related breakdown. Try providing shade for equipment that is prone to overheating and place these kinds of machines in an air-conditioned part of your business whenever possible. 

Troubleshoot the equipment: One important step is to properly diagnose any problems that do occur with a machine that has overheated. This should be done with the goal of getting the machine up and running as soon as possible so as not to slow down productivity. Often, if a particular malfunction has occurred and has been diagnosed in the past, then the whole troubleshooting process can be shortened considerably. Trouble shooting should involve: 

  • Verifying that a problem exist
  • Narrowing down the cause(s)
  • Correcting the problem
  • Work to prevent future issues

Use remote monitoring: One of the easiest things a manager can do is to monitor machine temperature remotely. If there is an odd spike in temperature that serves as a red flag for potential faults or defects elsewhere in the machine this can ultimately help catch a larger failure before it happens.

Finally, many problems that involve heat product related breakdown are caused by owners failing to protect their equipment. On our site, we will help you choose the right equipment for your industry and for the machine (s) you need to keep up and running.  

Why You Should Choose Your Next Cartridge Heater From Us!

With the huge selection of providers out there, we realize that choosing a cartridge heater can be difficult. At Jobco, Inc. we supply a complete range of cartridge heaters giving you a wide selection within a single site. In addition to cartridge heaters, we also sell other industrial machine parts such as sensors, temperature controllers, etc. Moreover, our products come from a huge variety of manufacturers such as Chromalox, Watlow, Osram Sylvania and more. This is why we think you should choose your next cartridge heater, coil heater, etc. from us. And to help you choose wisely from our vast selection of products and manufacturers, here are several factors that you should take into consideration:

Purpose 

What is the cartridge heater element needed for?

Cartridge heaters are used in a number of industries. Each of these industries has specific needs and requirements for their cartridge heaters. We have such a wide range of products that it will be easy for us to help you determine which heating element is appropriate for your specific needs. 

Materials

What materials need to be heated?

In order to maximize the efficiency of your heat transfer, you will need to know the types of materials that your cartridge heater will need to heat. We can help you by providing you with a heating element that fits the needs of your specific application. 

Temperature

What temperature does the cartridge heater need to reach?

The cartridge heaters you choose will need to be carefully selected if you want to prevent it from overheating. Choosing the wrong cartridge can damage the machine it is in and slow down or bring production to a complete halt costing you money while you seek a replacement. At Jobco, Inc. we can help you to determine which of our cartridge heaters best suits your requirements.

Size

What size cartridge heater element do you require?

Your cartridge heater will not work efficiently if you choose the wrong size. Some common cartridge heater sizes include: ½”, ¼”, ¾”, 3/8” and 5/8” or metric cartridge heater sizes of 6.5mm, 10mm, 12.5mm and 16mm. Just be sure to choose the right size for your machine. 

Density

What should the watt density of the cartridge heater you are looking for be?

Watt density is defined as the heating element power divided by the actively heated surface area of the element. Knowing this will make your selection easier as we have a wide range of cartridge heaters that meet all wattage requirements. Finally, we know that your company will be well served by any of the products we sell on our site as your company makes its push towards excellence and innovation.

Signs You are Dealing with a Disreputable Heating Element Seller

The heating element industry is growing bigger every day as more and more manufacturers appear on the scene and business demands increase. In this kind of situation, it is sometimes challenging for businesses to find reliable electric heating element suppliers. This uncertainty can create huge problems as businesses need to be able to keep their machines up and running. After all, a machine that is down and that needs to be repaired or replaced is one that robs a company of its profits. So how do you know when you are dealing with a heating element seller who does not have your best interest in mind? Here are some telltale signs:

  • The supplier does not ask you for specifications: Each businesses needs are unique when it comes to purchasing cartridge heaters or any other heating element. This is because different companies make different products and use a variety of machines. A reputable supplier will know this and ask that you be specific about how you will be using the element you are shopping for. He will ask you in order to help the transaction go smoothly and so that you do not have to spend too much or damage your machinery.
  • The supplier exaggerates the industrial heater lifetime: How long a heating element will last depends on several factors such as the environment in which it will be used, how often the machine will be in use and how the component is cared for. Therefore, no supplier can guarantee how long a part will last.
  • Price point is too high: You should shop around for comparable parts to determine the average cost of the item you are seeking to purchase.
  • Follow-up is difficult: Customer service is a important part of every business. At Jobco Supply, we know that you could be purchasing the elements you desire from countless other sites. This is why we strive to make your after purchase experience quick and pleasant. If you have a problem after the sale, you can contact us and we will try to make it right.

In the end, choosing the right heating element vendor does not have to be challenging. We can provide you with powerful and efficient radiant heaters as well as a Watlow cartridge heater and our coil heaters. We also sell temperature sensors & accessories to meet your commercial requirements. Our manufacturers are the top names in the business including Watlow, Osram Slyvania, Chromalox, Next Thermal and others.

Frequently Asked Questions about Cartridge Heaters

In order to get the most utility from your cartridge heater it is best to know all you can about it. Otherwise, you may be wasting time, money and creating a hazard for employees. If, for example, the wrong termination for a particular application is chosen this may lead to failure. So that you derive the best performance from your cartridge heater and assure the parts we sell you have a long life, we present these frequently asked questions about this product.

  1. What can be done to prolong the service life of a cartridge heater?

We’ve touched on this subject before but it is one that bears repeating. Obviously, you can get the most value from any machine part you buy by knowing how to use it properly. Cartridge heaters generally fail due to improper fit, too much moisture, contamination, movement, improper selection, improper installation and high watt densities. The best way that you can ensure that these conditions are avoided is to discuss your specifications with the company you are buying your cartridge from and to read all materials that accompany it.

  1. How long will a cartridge heater last?

This of course depends a great deal on how much and how often it is used. The exact factors that go into determining the longevity of a cartridge healer are temperature, duty cycles, heater design, the operating environment and controlling methods.

  1. How do I determine the correct hole diameter size for my application?

For Watlow products you can use this link to determine the proper hole diameter size.cartridge heater

  1. What is a medium watt density cartridge heater?

A medium watt density cartridge heater has a continuous resistance spiral throughout the heater. This makes it more reliable than other kinds of heaters.

  1. How much do heaters cost?

This depends on the specifications required for each application. Most manufactures allow customers to configure heaters to meet the specific requirements for which they will be applied. You can also consult with us about your specific needs and we can go from there.

  1. What Cartridge Heater Solutions can Jobco Provide?

Jobco is the smart choice for heat management. We have a variety of heater types form the leading manufacturers in the business. This can help you to get the heater your business needs rather than a general use cartridge. Choosing just the right cartridge heaters and coil heaters for custom use will help dramatically improve the durability, product quality, responsiveness and cycle time of your industrial machines.

5 Ways to Prepare Your Plant for Cold Weather

Fall is here and winter is fast approaching. For facility managers this can be a challenging time of year as cold weather is often challenging in term of keeping equipment and personnel operating despite the lower temperatures. Thus, now is the time to prepare for what may be a chilly fall/winter season ahead. Consider the following recommendations to prepare your facility for fall and winter weather.

  • Anticipate power failures and other winter-related disasters: Blizzards and ice storms can develop at almost any time during the winter and can knock out power in your facility for hours or even days. Thus, now it is a good time to plan for such a contingency. Make sure that you have a functioning generator on hand and that you can make the switch over to emergency power seamlessly. Also, educate your workers about blackout procedures so that they know how to respond if harsh weather brings your plant to halt.
  • Inspect your HVAC system: It is crucial that your heating and ventilation system be in good condition during the winter. After all, freezing conditions in your warehouse can damage equipment, inventory and most importantly affect the health and safety of your employees.
  • Outside piping: If you operate a gas plant, make sure the outside pipes are drained prior to the arrival of freezing weather conditions. Also, if your business has oil tanks on hand, consider using an oil tank heater blanket. Oil tanks need to be heated to a certain temperature so that the contents can maintain pumping viscosity and to prevent crystalline precipitation.
  • Check your equipment: Check all equipment that needs a heating element in order to function properly. If you have a Watlow cartridge heater or other kind of heater, make sure it is functional and that you take precautions to prevent it from failing in cold weather.
  • Review your building envelope: The first line of defense against cold weather is the outside of your facility. Does your building contain poorly insulated doors or windows? Does your roof need replacing? Are drafts a constants problem in your facility? If the answer to any of these questions is “yes”, then you should start winterizing your building’s exterior now.

To wrap things up, there is no need for your plant to be less productive during the winter. Take the necessary precautions now to protect products, men and equipment so that you do not encounter an emergency situation that ends up shutting down your operations. Also, browse our site for cartridge, band and immersion heaters. Our products can help to improve your facility’s safety and efficiency.

Tip for Increasing Molding Machine Productivity

Any successful method of controlling the quality and the cost of a product depends on how well the machines that produce that product are maintained. There is no getting around this fact. There is also no getting around the fact that the more productive a machine is the greater its output can be. This is just as true with molding machines as it is with any other factory machine. Unfortunately, injection molding machines are often overlooked by many businesses. In this post we’ll attempt to look at some ways to increase the productivity of this vital machine and at the same time your bottom line.

  • Dedicate several hours each quarter for maintenance checkups: Preventive maintenance helps save you money by reducing machine down time. It is also an opportunity to assess whether or not upgrades are needed and whether or not your machine is working at peak efficiency. The manpower time you use on checking your molding machine could pay huge dividend in uninterrupted production time.
  • Train your people well on the use of your injection molding machines: Take advantage of every available opportunity to train the people who will be using the machine on its proper use. This will make them more productive, less likely to damage the machine and better able to report on its inefficiencies.coil heater
  • Inspect machine hoses on a weekly basis: A hose rupture could cause your machine to cut off. If it does you will not only lose time and potentially cause a back up in your products, you will also have to clean up afterwards. To check for problems, feel for weak spots or signs of crimping in your hoses. This means that a particular hose may be nearing the end of its life. Take replacing hoses as seriously as you would replacing coil heaters or any other machine component.
  • Verify that your incoming power lines are tight at machine’s main breaker: If the power lines leading to your molding machine is loose it could lead to a fire. You should therefore check the power lines and the heater circuit of the machine.

Injection molding of plastics is a complex application that sometimes requires many different kinds of heaters. We carry several kinds of heaters including our Watlow cartridge heater, nozzle heaters, immersion heaters, etc.

Why Product Packaging Matters

One of the many uses of cartridge heaters is in the packaging of goods. Specifically, the lamination process requires quality cartridge heaters that are not prone to heat loss, failure, etc. Read on to learn more about why proper product packaging is so essential for businesses and how our cartridge heaters can aid the manufacturing process.

Safety: The most important function of a properly packaged product is to protect its contents. This is important because a product’s package must protect it not only as it travels from the manufacturer to the retailer, but it must also prevents its damage while the product sits on retail shelves. Cartridge heaters and other machine components that fail or that are improperly maintained or installed are likely to cause products to be sealed incorrectly. This can result in damage to items are that contained within the package. Additionally, poorly packaged products may even lead consumers to believe that the product has been tampered with in some manner. Finally, damaged items can cause customers to lose trust in manufacturers and the retailers who sell them such goods. (Remember the effects of the Tylenol scare of 1982?”)

Appearance: A consumer’s decision on whether or not to purchase is greatly influenced on how the wrapping it came in looks. And although many factors play a part of a person’s decision on whether or not to purchase any time, products that are attractive packaged undeniably have greater appeal to consumers.

Differentiation: Packaging helps differentiate a company’s product from others. The logos, color scheme, company name and information about the product may all be adversely affected when a package is improperly sealed.

Packaging creates brand recognition: The people who designed the packaging consumers see when they buy a product put a great deal of time and thought into the process. Every minute detail of the logo, colors and text they use on these packages is designed so that consumers will recognize and want to purchase that brand.

In short, quality cartridge heaters are vital to the packaging of certain items ranging from food and beverage to personal hygiene products. This is why it is important for manufacturers to purchase high quality custom cartridge heaters for their packaging machines. We sell a variety of custom cartridge heaters and hot air heaters from leading manufacturers like Watlow, Chromalox, Marathon, NexThermal, Tempco and others.

Four Ways to Optimize Performance of your Cartridge Heater

Increasing the efficiency of any machine or machine component can be a bit like found money for businesses. A well performing machine component is less likely to break down over its lifetime saving companies money and as they say ‘a penny saved is a penny earned.’ However, when it comes to optimizing machine or machine component performance there is one difference that and finding money –maximizing machine component efficiency does not occur by accident. It takes an effort and conscientious use of the equipment in question. These details can help you effectively improve the efficiency of your cartridge heater.

  • Protect the main heating element: The entire heating element of the cartridge heater should be immersed in the heating medium. This will prevent the heating element from exceeding the heat rating for the device. Moreover, make sure that the lead wire protrudes from the heater. This part could otherwise be overheated and damaged which can lead to costly repair or the need for a replacement.
  • Be careful when selecting the right heater: Selecting the correct wattage is of utmost importance when selecting a cartridge heater. The results of making the right selection in this regard will prevent failure and increase the performance of your cartridge. You can use factors like the medium to be heated, the desired operating temperature and process variables such as flow rate to determine the watt density of your heater cartridge. Next, its wattage should match closely with the application’s actual load requirements to limit it from cycling too often. We can help with our selection of customer cartridge heaters. We realize that every business is different and that every business owner has different needs, production goals, etc.heater
  • Prevent excessive heater cycling: A Watlow cartridge heater is among the most reliable kind of heater on the market but it is not invincible. Avoid excessive temperature cycling to guarantee the reliability and longevity of this machine workhorse. Excessive heater cycling causes severe stress and oxidation of the resistance wires inside a heater. Solid state relays (SSRs) and SCR power controllers can be used to minimize heater element recycling. (A solid state relay is electronic switching device that switches on or off when a small external voltage is applied across its control terminals.)
  • Regularly clean the surface: Dirt, grease and grime should not be allowed to accumulate on your heater. This will reduce heat transfer performance and cause the unit to become damaged.

Different machines and different businesses have different thermal demands. Moreover, optimizing your machine components performance should never be an afterthought. Choose one of our heaters and be assured that their manufacturers have behind them a wealth of industry knowledge.

Why Cartridge Heaters Fail

One of the key ways to lower equipment costs for any business it to make sure that each piece of equipment last as long as possible. And when it comes to heating equipment this can be quite a challenge. Logic would suggest that equipment such as cartridge heaters would naturally have a short life due to their very nature. However, cartridge failure is not always due to age. There are other factors that can lead to their failure. Here we outline some of the most common reasons why this happens and offer our top tips on how to prevent cartridge heater failure in the future.

  • Improper fit: Perhaps the most common cause for cartridge heater failure of all is improper fit. If a heater cannot dissipate the heat to the outside of its sheath properly the temperature will rise until it ultimately fails. Eventually, this will cause a breakdown of wires and heater itself.
  • The watt density is too high: All cartridge heaters have a voltage at which they are designed to work. Outside of this voltage rating they may be ineffective or may fail eventually. So, if the applied voltage is too high then this will increase the watt density of the heating element. This will result in heat not being dissipated in the way that it should. The result can be that the unit fails to operate.
  • Frequent temperature cycling: Excessive temperature cycling places undue stress on cartridge heaters. This can cause them to expand and contract at a fast rate (i.e. every 30-60 seconds). Eventually, this will reduce the lifespan of your heating element.
  • Moisture and impurities: These elements can be drawn into your heating cartridge from the surrounding environment. These two elements can often cause a short circuit to occur which can lead to the heater failing.
  • High temperatures and excess movement: Cartridge heaters can also be damaged by two other external factors – high temperatures and excess movement. To give your heater an added level of protection, make sure that you supply it with a suitable level of insulation when it is mounted onto moving machinery. In other words, the heating element should be as stable as possible or at the very least protected from excess movement which can lead to an eventual breakdown.jobco

The takeaway from all this is that just because your cartridge heater has a difficult job to perform does not mean that it has to burn out quickly. When certain precautions are taken your Watlow cartridge heater can have a life that is as long as any other vital equipment you own. Moreover, our customer cartridge heaters are made to fit the needs of all kinds of businesses. Check out our models and the specs and you will see how they can be an asset to your company.