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Reducing Energy Loss in Industrial Electric Heating Systems

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Industrial electric heating converts electrical input into heat at the point of use, but that does not mean every kilowatt reaches the process effectively. Heat can escape through vessel walls, piping, flanges and exposed surfaces. Energy can also be wasted through temperature overshoot, unnecessary standby operation, poor circulation, deposits or a heater that is mismatched to the required duty.

Improving efficiency begins with a heat balance and operating data, not with a single component claim. The most useful measures usually reduce avoidable losses, improve heat transfer and control output more closely. Final changes should be reviewed against the medium, temperature, pressure, flow, materials and safety requirements of the actual installation.

Identify Where the Energy Goes

A heater system uses energy to raise the temperature of the process medium, heat the vessel and connected equipment, compensate for ongoing surface losses and, in some applications, support phase change or chemical reaction. The required process heat is useful. Heat released to the surrounding area, excessive reheating and operation without production demand are potential losses.

Before changing the equipment, record inlet and outlet temperature, flow rate or batch mass, heater power, operating time, ambient conditions and production output. Comparing these values during stable operation helps distinguish a heat-loss problem from a process-capacity problem. A short measurement campaign is often more informative than relying only on the heater nameplate.

Improve Insulation Around the Complete Hot Zone

Insulation is often the first practical improvement because exposed metal surfaces lose heat continuously. The heater vessel is only one part of the hot zone. Flanges, valves, outlet piping, removable covers and supports can create significant thermal bridges. Damaged or wet insulation also performs poorly even when it appears present.

Insulation material and thickness must suit the surface temperature, environment and maintenance needs. Removable insulation jackets can preserve access to flanges and instruments. External surface temperature should be checked after installation, and insulation should not cover terminals, cooling openings, sensors or components that require ventilation.

Loss source What to check Possible action
Vessel and piping surfaces Hot spots, missing insulation and damaged cladding Repair or redesign insulation while preserving maintenance access
Temperature overshoot Trend data after start-up or load changes Tune control parameters or use proportional power control
Poor heat transfer Flow, deposits, sludge and product viscosity Restore circulation, clean surfaces or review element loading
Idle operation Heater on-time compared with production demand Add operating schedules, standby setpoints or automatic shutdown

 

Match Heater Capacity to the Real Duty

An oversized heater can shorten heat-up time, but it may also cycle aggressively at low load and create overshoot if control resolution is limited. An undersized heater may run continuously without reaching the target temperature. Capacity should be based on the mass or flow being heated, heat capacity, temperature rise, required heat-up time and estimated losses.

Variable production deserves special attention. Staged heater banks or modular elements can match output to changing load more effectively than one large on-off stage. The electrical supply, switching components and control sequence must be designed for the selected staging arrangement.

Use Control That Fits the Thermal Response

Simple contactor control may be appropriate for slow processes with wide temperature tolerance. Processes that react quickly or require stable temperature may benefit from SCR power regulation. Smooth control can reduce overshoot and repeated full-power cycling, but it does not eliminate losses caused by poor insulation or unsuitable equipment sizing.

Sensor location is equally important. A sensor placed too far from the heated zone may respond slowly, while a sensor exposed directly to radiant heat can report a value that does not represent the process. Trend recording can reveal oscillation, delayed response and unnecessary heating after production stops.

Maintain Heat Transfer Surfaces and Flow

Scale, carbon, sludge and product residue act as insulation on the element surface. The heater then operates at a higher sheath temperature to deliver the same useful heat. Deposits can therefore increase energy use and reduce element life at the same time. Cleaning intervals should reflect water hardness, fluid condition, solids content and actual inspection findings.

For circulation heaters, verify pumps, filters, valves and minimum-flow interlocks. Low flow reduces heat-transfer performance and can create local overheating. Air and duct heaters likewise depend on adequate, well-distributed airflow across the elements. Restoring the design flow may improve both energy use and reliability without increasing installed power.

Recover Heat Where the Process Allows

Some systems can preheat incoming material using heat from an outgoing stream, hot exhaust or a return circuit. Heat recovery requires a suitable heat exchanger and careful review of contamination, pressure drop, corrosion and control interactions. It should not be assumed that every hot stream is economically or technically recoverable.

A Practical Efficiency Review
  • Record power, operating hours, temperatures, flow or batch size and production output
  • Inspect insulation, hot surfaces, flanges, piping and removable covers
  • Review heater capacity against normal and minimum production loads
  • Check sensor position, control stability and temperature overshoot
  • Inspect deposits and confirm cleaning or descaling intervals
  • Verify pumps, fans, filters, valves and minimum-flow protection
  • Identify standby periods and unnecessary heating outside production hours
  • Evaluate heat recovery only after confirming process compatibility
Conclusion

Reducing energy loss in industrial electric heating requires attention to the whole system. Insulation, correct capacity, stable control, clean heat-transfer surfaces, adequate flow and disciplined operating schedules usually matter more than a single efficiency label. Measurements before and after changes provide the clearest evidence of improvement.

Runkel manufactures customized industrial electric heaters, heating elements and control solutions for confirmed process conditions. Customers can provide operating data, drawings and current energy-use information for technical evaluation. Final equipment selection and expected performance depend on the verified application and operating profile.

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Top 6 Industrial Electric Heater Manufacturers in 2026 | Runkel Electric Heating
Runkel Electric Heating

Top 6 Industrial Electric Heater Manufacturers in 2026

Six brands that supply industrial and explosion-proof electric heaters, compared on origin, range and hazardous-area offer, with the checks that matter before you ask for a quote.

Published October 20, 2026 by Runkel Electric Heating. Company facts checked October 2026.

The six brands at a glance

Two of the six share an owner: Spirax Group owns both Chromalox and Vulcanic. Caloritech is the process-heating brand of Thermon. EXHEAT, Runkel and Watlow are covered one by one below.

Brand Founded Based in Core range Hazardous-area offer
Caloritech (Thermon) 1954 Austin, Texas, USA Process heaters, electric boilers, heat tracing Ruffneck explosion-proof unit and convection heaters. Not every Caloritech model is hazardous-rated.
Chromalox 1917 Pittsburgh, Pennsylvania, USA Industrial heaters, heat tracing, packaged systems, controls Ex d and Ex e heaters for Zones 1 and 2, per a UK distributor listing.
EXHEAT Not verified United Kingdom Hazardous-area heaters and controls ATEX, UKEx and IECEx products: enclosure, air, immersion and portable fan heaters.
RunkelPublisher of this guide 2015 Qingdao, China Explosion-proof, circulation, bundle and duct heaters; tubular elements; PTC; cartridge heaters Explosion-proof series, rated by model. Circulation units up to 3,000 kW.
Vulcanic 1973 Neuilly-sur-Marne, France Immersion, flow and air duct heaters, cables, controls ATEX immersion heaters, flow heaters and radiators.
Watlow 1922 St. Louis, Missouri, USA Heaters, sensors, controllers, system assemblies Not detailed in the sources we checked. Ask for model-level certificates.

Scroll sideways on a phone to see every column. “Not verified” means we could not confirm the detail from the sources listed at the end of this page.

Caloritech (Thermon)

Parent company
Thermon Group Holdings
Founded
1954
Based in
Austin, Texas, USA

Caloritech is the process-heating brand of Thermon, a US company best known for heat tracing. Thermon’s Ruffneck line covers explosion-proof electric unit heaters and convection heaters built for oil and gas sites, and the Caloritech name also appears on electric boilers.

Best fit: North American process-heating projects that also need heat tracing from the same supplier.

Check first: some Caloritech models, such as the BX convection heater, are not intended for hazardous locations. Confirm the certification of the exact model you plan to buy.

Chromalox

Parent company
Spirax Group
Founded
1917
Based in
Pittsburgh, Pennsylvania, USA

Chromalox is one of the oldest names in electric heating. Its first product was a strip heater, and it has been part of Spirax-Sarco, now Spirax Group, since 2017. It sells industrial heaters, heat tracing and packaged heating systems. UK distributor listings describe Ex d flameproof and Ex e increased-safety heaters for Zone 1 and Zone 2.

Best fit: large projects that want packaged systems and controls from one global brand.

Check first: lead time and local service cover for custom units, which can vary by region.

EXHEAT

Founded
Not verified
Based in
United Kingdom
Certification listed
ATEX, UKEx, IECEx

EXHEAT builds hazardous-area electric heating and control equipment in the UK. Its catalogue runs from small enclosure heaters and air warmers to tank immersion heaters and a portable fan heater, with ATEX, UKEx and IECEx certification listed through its UK distributor.

Best fit: smaller hazardous-area jobs, such as cabinets, workshops and compact tank heating, where UK or European certification is required.

Check first: the sources we used did not confirm EXHEAT’s founding year or ownership, so verify both directly with the company.

Runkel

Group
Yangzhong Sanhuan Electric Heating Group
Founded
2015
Based in
Qingdao, China
Quality system
ISO 9001:2015

Runkel Electric Heating was set up in 2015 as the foreign-trade arm of the Yangzhong Sanhuan group and works with group plants in Yangzhong, Shijiazhuang and Shenyang. Its 2026 brochure lists explosion-proof, circulation, bundle and duct heaters, food-grade explosion-proof heaters, tubular and liquid heating elements, PTC heaters, cartridge heaters, flexible ceramic heaters, bolt heaters and tube-production machines.

Circulation heater units are listed at 380 V up to 3,000 kW, and high-temperature duct heaters from 10 to 3,000 kW at 220 to 380 V.

Best fit: buyers who want a China-based maker to engineer custom explosion-proof, circulation or duct heaters to a specification, with price as a deciding factor.

Check first: the certificates shown in Runkel’s brochure are issued to group manufacturing companies, so request the one that names your model, zone and temperature class.

Two explosion-proof bundle electric heaters, one with an orange terminal housing and one with a grey housing
Explosion-proof bundle heaters from Runkel’s 2026 product brochure.

Vulcanic

Parent company
Spirax Group (since 2022)
Founded
1973
Based in
Neuilly-sur-Marne, France

Vulcanic has made electric heating and cooling equipment since 1973. Its range includes immersion heaters, flow heaters, air duct heaters, heating cables and controls, with ATEX versions of the immersion and flow heaters. Spirax Group agreed to buy it in 2022, so it now sits alongside Chromalox.

Best fit: European sites that need ATEX-marked immersion or flow heaters.

Check first: the notified body and certificate number printed in the ATEX marking of your model.

Watlow

Founded
1922
Based in
St. Louis, Missouri, USA

Watlow designs industrial heaters, sensors, controllers and system assemblies. That mix of heating and control hardware suits projects that need the whole thermal loop from one supplier.

Best fit: equipment makers and process lines that need heaters matched with sensors and controllers.

Check first: the sources we used did not detail Watlow’s hazardous-area range, so ask for model-level certificates.

How to choose an electric heater manufacturer

Start with the hazardous area. The zone tells you how often an explosive gas atmosphere is present, and it sets the protection type and certificate you need.

  • Zone 0 More than 1,000 hours a year Explosive gas is present continuously or for long periods.
  • Zone 1 10 to 1,000 hours a year Explosive gas is likely to appear in normal operation.
  • Zone 2 0.1 to 10 hours a year Explosive gas is not expected in normal operation and, if it appears, is brief.
Protection type Ex d flameproof, Ex e increased safety or another type, matched to the zone and the heater design.
Certificate ATEX, IECEx, UKEx or the national scheme of the destination country. It should name the exact model, not just the product family.
Medium and temperature What is being heated, the target temperature, the working pressure and the temperature class required.
Power and supply Total kW, supply voltage, phases and the number of heating stages.
Protection devices Overcurrent, overvoltage, phase-loss and over-temperature protection, and whether the heater connects to a DCS.
Documents and support Drawings, test reports, lead time, spare parts and who handles site questions.

Frequently asked questions

Who are the top industrial electric heater manufacturers in 2026?

This guide compares six brands: Caloritech (Thermon), Chromalox, EXHEAT, Runkel, Vulcanic and Watlow. They are listed alphabetically rather than ranked, because the best fit depends on hazardous-area rating, power range, region and budget.

What is the difference between Ex d and Ex e electric heaters?

Ex d (flameproof) heaters use an enclosure that can withstand an internal explosion and stop it igniting the atmosphere outside. Ex e (increased safety) heaters add design measures that prevent arcs, sparks and excessive temperatures during normal operation.

Do Chromalox and Vulcanic belong to the same company?

Yes. Both are owned by Spirax Group, which bought Chromalox in 2017 and acquired Vulcanic in 2022.

What should I ask a manufacturer before buying an explosion-proof heater?

Ask for the certificate that names your exact model, the hazardous zone and temperature class it covers, the maximum medium temperature and pressure, and the protection devices fitted. Also confirm lead time, drawings and spare-part support.

Send us your heater specification

Share the medium, target temperature, power, voltage and hazardous zone, and Runkel’s engineers will reply with a proposal and quotation.

Email info@runkel.cn
Telephone
+86 13360463744, +86 13904545333
Email
info@runkel.cn
Address
46th Floor, Qingdao Wanbang Center, No. 2 Hong Kong Middle Road, Shinan District, Qingdao, Shandong Province, China

Sources and method

Facts were checked in October 2026 against the pages below and Runkel’s own 2026 product brochure. Company details can change, so confirm them with each vendor.

Top 6 Industrial Electric Heater Manufacturers in 2026

Top 6 Industrial Electric Heater Manufacturers in 2026

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