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6 Ways to Increase Manufacturing Productivity

Regardless of whether your company is manufacturing or service oriented, it must remain productive to stay in business. After all, the more production you can squeeze out in a period of time, the more money your company can make the more competitive it will remain. For your convenience, we’ve narrowed the list down to the top 6 ways how to increase productivity in manufacturing.

  • Review your current workflow: The best way to figure out where you want to be is to first figure out where you are. By this we mean that your company can increase productivity in manufacturing by first defining which areas of your workflow are lacking. Go over who your employers are, what equipment you use, how training is implemented etc.
  • Keep your equipment working properly: Damaged equipment can lead to unscheduled downtime which is never good for business. Therefore, you should regularly inspect your equipment and be prepared to replace parts or even whole machines as needed. 
  • Improve training: There is no substitute for well-trained workers. In order to maximize productivity, train your employees to be able to handle multiple processes. This way the workflow will be uninterrupted if an employee is on vacation or is absent for any other reason.
  • Capitalize on manufacturing tech trends: Keep up to date with the latest manufacturing trends and technologies. This way your company will always remain competitive and never be left behind.
  • Organize the workspace: Optimize the design of your factory in a manner that reduces travel time and distance between various tasks. You should consider software to help you design the optimum workspace for your manufacturing plant. 
  • Engage your employees: Managers are not the only ones who have ideas about how to improve productivity. For this reason, you should strive to open channels of communication so that employees can effectively communicate up the chain when they have suggestions, comments or complaints.

There are certain obstacles that all businesses face. The easiest way to overcome them is to take an objective look at what is wrong currently and how it can be corrected in the future. Hopefully, using these tips you will be on the way towards making your manufacturing plant more productive and efficient. It can take a fair bit of effort to get the ball rolling, but the investment in strengthening manufacturing productivity will be worth it in the long run. We can help you with premium coil heaters and custom cartridge heaters from some of the leading manufacturers in the world.   

 

The Advantages of Quartz Heaters

Quartz is a hard and shiny stone used in electronic equipment, generally in watches. Quartz heaters contain some of the most efficient types of heating elements available. They convert 100% of the electrical energy used into heat. The many advantages that quartz heater offer for businesses include: 

  • Even heat distribution: Quartz infrared rays heat the objects directly. They provide steady heat evenly and consistently from whatever location they are placed.
  • Affordability: Quartz infrared heaters are more affordable than other sources of heating. The cost of maintenance is also low for quartz heaters. For example elements heaters last for 3 to 5 years and their cost is about $25. Moreover, since quartz electrical heaters are more energy efficient as they heat objects, they take less time and consume less energy,
  • Quartz heaters are durable: Quartz heaters can last for many years. Even the maintenance required for this type of heater is less.
  • Safe and secure: Quartz infrared heaters are safe in commercial and residential settings because they do not burn oxygen like other heaters do. Quartz infrared heaters use electricity as their heating source. For this reason, they do not release toxic gases and are environmentally friendly.

4 Factors to Consider when Choosing a Heating Element

Budget – Quartz heaters are more efficient than ceramic heating elements. Thus, although they may not outwardly appear to cost less, they do save money in the long term.

Application – You need to consider where your new heating element will be positioned.

Safety – Quartz heaters should be situated at least 3ft away from walls, furniture and other objects to avoid hazards


Speed – Quartz heaters that have become renowned for their ability to heat up quickly and perform at high speeds.

To wrap things up, quartz heaters are efficient and can save businesses money. 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 a quartz heating element, as well as band and immersion heaters. Our products can help to improve your facility’s safety and efficiency.  

 

Reason You Need an Oil Tank Heater Blanket

Fall is here and winter is fast approaching. For facility managers, this can be a difficult time of year as cold weather is often challenging and they must keep equipment and personnel operating despite the lower temperatures. What can oil and gas companies do to ensure their product is kept safe from winter weather? One solution is to use an oil tank heater blanket. Here are some of the main reasons why you should consider purchasing one for your company. 

 

  • Heater blankets can help maintain proper oil flow: In the oil and gas industry, winter means frozen pipes and faulty equipment. It can also mean that the flow of oil from your tanks and into its pipes can be greatly slowed down as the cold weather increases the viscosity of oil. In fact, under certain circumstances oil can run more like sludge than oil. An oil tank heater blanket can keep fluids at optimum flowing temperatures, letting your oil move through pipelines as it should.

  • Heater blankets increase with storage capacity: Natural gas and propane both naturally condense in cold weather. The result can decrease the pressure in the tanks in which they are stored. This reduction decreases the amount of gas you will have to work with. An oil tank heater blanket can resolve this problem by preventing your tanks from getting too cold. Thus, they will be able to maintain the right amount of pressure. This will stop gas from dissipating in the form of vapor.

  • Heater blankets help prevent valves from freezing: The oil inside tanks is not the only thing that a heater blanket can protect. It can also protect valves which often freeze up during the winter months. Additionally, keeping valves open and in good operating condition can help you avoid serious safety issues. 

To wrap things up, there is no need for your plant to be less productive during the winter simply because you do not have an oil tank heater blanket. 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. Browse our site for cartridge, band and immersion heaters too. Our products can help to improve your facility’s safety and efficiency.  

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. 

Molding Machine Maintenance Tips

One of the most common uses of our heating elements is in molding machines. Although preventative molding machine maintenance seems like it should be a no-brainer, some owners take these machines for granted. This is when problems occur that can affect a business. To prove that the importance of preventative maintenance isn’t a mystery, here is some information about molding machines and how to keep them in tip top shape.

 

  • Conduct a maintenance check before and after every cycle: The whole idea of machine maintenance is to catch problems before they develop. By conducting a check with every cycle, you will be able to keep parts to spec and ensure that no debris or other foreign matter can damage the mold.

  • Clean mold cavities with a gentle solvent: One drawback to mold machines is that residue can begin to accumulate within the cavity affecting the shape of your parts. The solution: Clean your mold using a gentle solvent so that you can avoid this problem from occurring and potentially damaging your machine and your products.

  • Use compressed air to blow out dust, debris and water: Sometimes a gentle solvent alone is not sufficient to clean out more complex molds. In these cases, compressed air is usually enough to clean out molds before they can cause damage during the production cycle.

  • Be sure that the entire mold dries before storing: Water can damage metal molds. Be sure that you dry your mold if you choose to clean them with water as rust can develop and result in a large proportion of rejected pieces.

  • Note when maintenance was last performed: Make sure that you know when maintenance was last performed on your machine(s) and who conducted the inspection. This will let you know when the next check is needed and will help to keep employees accountable for regular maintenance.

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. We sell a variety of products from oil tank heater blankets to strip heaters.  

 

Coil Heaters: Types and Uses

Heater coils are mostly resistive elements that consume whole active power and dissipate the same as heat. It uses the Jule effect (H= I2 x R x t), in order to produce this heat. Overheating is the main cause of heater failures since every heater has a certain power dissipation capability beyond that it can fail. Knowing the options available and the common uses for each electric coil heater type can help you, as a businessperson, choose the best coil heater for your needs. Let’s look at various kinds of coil heaters and their uses. 

  • Flat coil heater: This kind of heater is relatively simple in design. It is a heater that is wound around a flat coil. Thus, it is easy to place inside a variety of objects due to this flat shape. Uses: This kind of heater is most often used in injection molding machines for plastic and metal of varying sizes. Warning: Do not use this coil for temperatures exceeding 1000 F for extended periods of time.

  • Maxi coil heaters: These have larger physical dimensions (10mm wide x 3.8mm high) and are suitable for increased wattage and robust working condition requirements. Their bigger size makes them ideal for large injection molding machines or large die casting machines and metal molding equipment.

  • Axial clamp heater: Axial clamp mini coil heaters are a proven performer for high cavitation applications including pre-forms, caps and closures, and razors. This kind of heating element is suited for high caution applications.

  • Formable coil heater: As the name implies, a formable coil heater is a heater that can conform to a variety of shapes without damaging the heating elements contained within. Because this element is so flexible, it is excellent at heating challenging objects.

  • Round coil heater: Round coil heaters are simple in design and are capable of heating a variety of tricky objects. 

So, which coil heater you use depends on your business needs. We can provide you with powerful and efficient radiant heaters as well as a Watlow cartridge heater and coil heaters. We also sell temperature sensors and accessories to meet your commercial requirements. Our manufacturers are the top names in the business including Watlow, Osram Slyvania, Chromalox, Next Thermal and others.