|Matrusree has set industry standards as the leading manufacturer of Aluminum, Brass and Bronze Cast-In Heaters in a variety of standard designs and styles. However, we understand not every Cast-In Heater application can be solved by one of our standard products. Our solutions help our customers and create new opportunities for Matrusree. It is our engineering talents and enormous application knowledge that provides a winning combination for solving precise application problems with the right Cast-In Heater. The design engineering and manufacturing of Matrusree Cast-In Heaters is done under one roof-administered by a team of experienced professionals with a vast knowledge in product design and proven foundry capability, producing the best quality Cast-In Heater money can buy. Aluminum Cast In Heaters offer a high quality and efficient method of heating and controlling Extruders, Compression Molding Platens, Heat Sealers, Vacuum Forming Platens. The heat cool capabilities of Aluminum Cast In Heaters provide high accuracy temperature control of +/- 2 degrees. These precision Aluminum Cast In Heaters are available in various sizes and watt densities ranging from 10 t0 60 watts per square inch. |
Aluminum Cast In Heaters are pressure casted insuring a dense porosity free casting that can been supplied with either cooling fins or seamless stainless steel cooling tubes that guarantee longer life.
Aluminum Cast In Heaters can be casted into any shape and size needed, thus fully covering the part to be heated and virtually becoming the part itself. Most Cast In heat cool bands are made to customer specifications, but standard sizes are available out of stock.
Aluminum Cast In Heaters are contamination and corrosion resistant and can with stand high temperature and pressures in harsh environments with years of trouble free service.
|Aluminum Cast In Heaters Features: |
1. High operating temperatures|
2. Liquid cooling or air-cooling fins
3. Any size or shape available
4. Pressure casted ensures porosity free high density casting
5. Extremely ruled and resistant to damage
6. Precise and accurate control of temperature due to heat cool action
7. High watt densities available
Voltage: 240-415 volts|
Casting Material: Aluminum, Brass, Cast iron
Termination's: Leads, Terminal Boxes, Screw/Threaded Studs
Wattage: Aluminum Up to 25 W/in2 and Bronze Up to 30 W/in2
Options: Holes, Grooves, Notches, Cutouts, Available
- Die Heating
- Foodservice Equipment
- Glue Pots
- Heat Sealing Equipment
- Heat Treating Equipment
- Hot Melt Dispensing Equipment
- Hot Stamping Machinery
- Laminating Equipment
- Medical Equipment
- Packaging Machinery
- Plastics Machinery
- Process Pipelines
- Solvent Reclaim Equipment
- Research and Development
- Semiconductor Processing
- Silk Screening Equipment
- Textile Manufacturing
- Vacuum Forming
|MATRUSREE's CAST-IN band heaters have proven to be the most effective method for heating and cooling the barrels of plastics processing extruders. They are extremely efficient, providing thousands of hours of dependable, trouble free service. Specifically for close contact heating enabling precise heat conduction. Cast Aluminum heaters are machined to fine limits and complex patterns are achieved. They can be produced to your specifications or drawings, alternatively, against your sample. MATRUSREE offers CAST-IN band heaters with liquid and/or air-cooling functions. Liquid cooling incorporates tubing formed to a specific shape and casted as part of the heater assembly creating a passage for processing water or heat transfer solutions to dissipate the heat. Air-cooling incorporates numerous fins casted to the O.D. surface of the band.|
|The heat sources for MATRUSREE's CAST-IN heaters are tubular heating elements. They can be formed into endless configurations to Accommodate any practical CAST-IN heater shape or formed and casted in and around machine component parts such as fluid transfer pipes, valves, reducers, tees, elbows, and other special assemblies requiring localized heat. The sheath material is Stainless Steel and heater diameter will vary depending on CAST-IN heater design. Aluminum is the predominant alloy used for CAST-IN heaters. Brass is used when the operating temperature required exceeds those of Aluminum. Also recommended for heated platens on molding presses as Bronze can withstand more pounds per square inch of pressure.|
|Habitually, liquid cooled Cast-In Heaters have been the more frequently employed method of controlling the melt temperature of extrusion barrels. There is no doubt about the effectiveness and speed of liquid cooled castings in removing heat from the extrusion process. However, there are some drawbacks that primarily relate to maintenance-associated issues. Air Cooled Cast-In Heaters are virtually maintenance free and therefore, when properly installed and applied, have the capability to far outlast their liquid cooled counterparts. Since cooling tubes are not used, the possibility of breakage, cracking or becoming clogged with brine or mineral deposits is not a concern. |
|Additionally, Air Cooled Cast-In Heaters do not require an expensive cooling tower or heat exchange system, extensive plumbing systems and labor for installation. These factors along with the benefit of being maintenance free make MATRUSREE's Air Cooled Cast-In Heaters an economical and practical source for your extrusion heating and cooling application. |
|In certain instances where air-cooling alone will not sufficiently cool the process, liquid cooling tubes can be cast into the heater as well to maximize BTU removal|
|Our Cast-In Band Heaters have proven to be the most effective method for heating and cooling the barrels of extruders used in plastics processing. Matrusree offers Cast-In Band Heaters with liquid and/or air cooling. Liquid cooling incorporates tubing cast in as part of the heater assembly, allowing water or heat transfer solutions to remove the heat. Air cooling uses fins cast to the O. D. surface of the band heater; blowers and specially designed shrouds aid in heat removal. Aluminum is the predominant alloy used for the Cast-In Heater. Copper based alloys (Bronze and Brass) are used when the required operating temperatures exceed the maximum for aluminum. Bronze or brass is recommended for heated platens in molding presses as they can withstand a greater force per square inch than aluminum.|
|Tubular Heater Diameter:
|Maximum Amps per element:
Three Phase available depending on Casting Size
Resistance Tolerance: 10%, 5%
Wattage Tolerance: 5%, 10%
Maximum Watt Density Aluminum Alloy-35 W/in2 on the element
Maximum Watt Density Bronze or Brass-45 W/in2 on the element
| Aluminum 319 (Standard)
|Aluminum 356 (Optional)
|Aluminum 443 (Optional)
|Aluminum 355 (Optional)
|Minimum Inside Diameter
|Maximum Inside Diameter
||1/4" top and bottom or to customer specification
The following special features can be incorporated into Cast-In Heater designs. Specify exact dimensions and locations.|
- Taper Angles
- Thermo wells
- Electrolyses Nickel Plating
- Teflon® Coating
- Mounting Studs
- Ground Studs
CONSTRUCTON IN DETAIL:
Having in-house foundry capabilities gives us the flexibility required to apply sound foundry techniques to control the quality of each casting. Specially designed steel and cast iron molds are used in our Permanent Mold Casting Process, producing a dense casting free of internal voids and drastically reducing porosity, resulting in smoother as-cast surfaces. When processing small quantities, No-Bake Sand Molds are used. This sand casting process produces a better quality casting than other sand processes. The inside diameter of all Cast-In Band Heaters is machine finished to customer specifications
INCOLOY COOLING TUBES:|
The most important part in the design of a heat and liquid cool Cast-In Heater is the cooling tube itself, since cooling tube failures usually occur before heating element failures. Matrusree has devoted many years of testing and research to develop an alloy tube that is resistant to corrosion, and that will also withstand the continuous stress that is placed on the cooling tube.
Our testing has shown that Incoloy® tubing performs best with exposed cooling tube extensions under these harsh conditions, versus stainless steel tubing. Incoloy® is also less susceptible to carbide precipitation; a product of the thermal shock of repetitive heat/cool cycling that produces internal stress corrosion cracking, a common failure of the cooling tube. We have also learned that using tubing with a .049-inch-thick wall is essential to prevent cracked cooling tubes due to linear thermal expansion as they exit the Cast-In Heater.
Cooling tube extensions can be cut to your specified length, with various types of tube fittings factory installed. The casting can also be supplied with non-exposed cooling tube fittings, which reduce cooling tube failure due to stress.
TUBULAR HEATING ELEMENTS:|
To maintain lower watt densities important for good heater life, the largest possible diameter steel sheath tubular heater is used. Matrusree most commonly uses a .430 diameter element with 1/8" diameter cold pins. This pin size allows installation of larger and stronger screw terminal connections, providing additional strength to prevent broken terminals due to mechanical abuse.
Specially designed, low expansion 430 stainless steel clamping straps with 1/4"-20 socket head cap screws and barrel nuts, in either 3/4", or 11/4" widths, are supplied as our standard method for securing the casting to the barrel. The number and width of the straps is determined by the length and weight of the heater.
Threaded post terminals with 10-32 threads are securely fastened to the tubular heating element cold pin, assuring positive electrical contact for maximum amperage carrying capacity. Other terminations are available to accommodate your requirements.
The standard Type "S" terminal has specially designed ceramic insulators that provide support to the screw terminals. The tubular heater is recessed into the insulator, to help prevent the screw terminals from bending or breaking from mechanical abuse. Other specially designed ceramic insulators are available for the screw terminals and the connecting wire.
General purpose steel terminal boxes provide a simple and economical way to eliminate exposure to live electrical terminals. To simplify electrical wiring, the box has two knockouts for standard 3/8" BX cable connectors. Boxes can be supplied factory prewired with high temperature lead wire protected with armor cable or wire braid. Other boxes are available to accommodate your requirements.
- Laminating Equipment
- Injection Molding
- Vacuum Forming
- Extrusion Die Heads
- Compression Molding
- Blow Molding
- Heat Sealers
- Food Processing
- Silk Screening
- Laboratory Equipment
- Tire Making Machines
In the plastic extrusion process, the cooling function of the Cast-In Heater is in fact its most important function. The cooling function of the Cast-In Heater has a considerable role in modulating the melt temperature of the plastic in the extruder barrel. In conventional extrusion applications, the liquid cooled method is the most commonly employed. Essentially, this is due to the constructional characteristics of the liquid cooled style cast-in, which facilitates extremely rapid, precise and uniform removal of heat from the extrusion barrel. This quick response-time capability has made Matrusree's liquid cooled Cast-In Heaters the primary choice of the extrusion industry. Because the liquid cooling function of the Cast-In Heater is of primary importance to the extrusion process, Matrusree offers many different liquid cooling variations, styles and terminations. Matrusree manufactures custom Cast-In Heaters to exact specifications, meeting the requirements of your process. Matrusree also offers bountiful common sizes and styles of Liquid Cooled Cast-In Heaters off the shelf for immediate delivery.
SINGLE SET OF COOLING TUBES:|
The single set cooling tube design features 1/4", 3/8" or 1/2" diameter tubing accurately formed into a circuitous or any other suitable shape and cast into the body of the Cast-In Heater. This is the most widely used method for providing a means of cooling on liquid cooled Cast-In Heaters.
Type CW Cast-In Band Heaters consist of liquid cooled and/or heating functions, and are secured to the extruder barrel with 3/4" or 1 1/4" wide low expansion stainless steel clamping straps with 1/4"-20 socket head cap screws and barrel nuts.
If not otherwise specified, supplied with Type S electrical screw termination, 3" long cooling tube extensions and straps for clamping.
Type CWB Cast-In Band Heaters consist of liquid cooled and/or heating functions, and are secured to the barrel by bolts clamping the two halves together around the barrel. A variety of bolt clamping designs and hardware are available. Consult Matrusree with your specific requirements.
Dual Set of Cooling Tubes:|
The Dual cooling tube design incorporates two sets of 3/8" or 1/2" diameter tubing formed into a serpentine or any other suitable shape within the same Cast-In Heater. Dual cooling tubes will actually double the operating life of a Cast-In Heater with liquid cool function, since cooling tube failures usually occur before heating element failures
There are two main causes for failure on liquid cooled Cast-In Heaters: Stress corrosion cracking at the exiting point of the tube extensions and clogged lines due to scale build-up that reduce flow, decreasing cooling capacity, and finally completely blocking the tube. Once the first set of cooling tubes has failed, reconnect to the spare set and you are back in operation, thus eliminating costly downtime and additional labor for heater replacement. Dual cooling tubes are also used when additional cooling capacity is required. Cooling tube extensions can be factory equipped with your choice of fittings. Clamping styles are low thermal expansion alloy straps or bolt clamping. If not otherwise specified, supplied with Type S electrical screw termination, 3" long cooling tube extensions and straps for clamping.
- Double operating life
- Greater reliability
- Reduces costly downtime
- Double cooling capacity
- Reduces heater replacement inventory
- Various heater terminations
- Made to customer specifications
Dual Set of Unexposed Cooling Tubes :|
The recessed cooling tube design incorporates 3/8" or 1/2" diameter tubing formed into a serpentine or any other suitable shape with specially designed stainless steel NPT fittings that are welded to the tube ends and cast below the surface of the Cast-In Heater, thus eliminating the troublesome, commonly used tube extensions as they exit the casting for connection to the coolant lines. Non-exposed fittings will drastically increase the operating life of a Cast-In Heater with liquid cool function as this feature eliminates broken and/or damaged cooling tube extensions, which are a major factor in premature heater failure. Type RC fittings are available in two female NPT thread sizes, 3/8"-18 and 1/2"-14. Standard clamping styles for Cast-In Band Heater sets are low thermal expansion alloy straps or bolt clamping. Specify fitting thread size and clamping style when ordering. If not otherwise specified, supplied with Type S electrical screw termination and straps for clamping. For fittings with special thread size, consult Matrusree with your requirements.
- Quick and easy installation
- Exceptionally longer Cast-In Heater life Reduces costly downtime
- Greater reliability
- Rugged durable construction
- Available on all cooling tube sizes
- Made to customer specifications
| Cooling Tube Termination Options:|
Brazed Seal Fittings:|
Brazed seals are excellent for high pressures and temperatures. Recommended to be factory installed to assure good braze seals. Available for 3/8" and 1/2" diameter tubing.
Flared Seal Fittings:|
Brass flared seal fittings are well adapted for low to medium pressure and resistant to mechanical pullout. Available for 3/8" and 1/2" diameter tubing with SAE 45° flare.
Hi-seal fittings are highly dependable under the most adverse conditions. For reliable and trouble-free service with ease of installation, we strongly recommend hi-seal fittings. Available for 3/8" and 1/2" diameter tubing. Male thread is 1/2" NPT for 1/2" tube and 3/8" tube. Fitting is brass.
Ceramic Insulated terminals:|
Heavy duty ceramic insulator for .430" diameter heater with 10-32 screw threads. Standard on Cast-In Heaters unless otherwise specified.
Mica Insulated Terminals:
Mica insulator is the same diameter as the heating element. Available for .260", .315" and .430" diameter heaters. .260" diameter has 6-32 terminal; .315" and .430" have 10-32 terminals.
Ceramic insulated terminals type 2:
Ceramic insulator is the same diameter as the heating element. Available for .260", .315" and .430" diameter heaters. .260" diameter has 6-32 ; .315" and .430" have 10-32 terminals.
Heavy Duty Ceramic Insulator Terminal:
Heavy duty ceramic insulator with terminal cover for screw terminal 10-32 thread. Available for .315" and .430" diameter heaters
Right Angle Lug Terminal:
Right-angle lug welded to pin with mica washer insulators and 10-32 binding head screw. Available for .260", .315" and .430" diameter heaters.
Terminal Lug Terminal:
Terminal lug spot welded to pin with 10-32 binding head screw. Available for .260", .315" and .430" diameter heaters. Type L represents straight; Type L9 represents 90° to pin. Specify lug orientation
90/ Blockhead Screw Terminal:
Mica washers with 90° blockhead screw terminal with 10-32 screw threads. Available for .260", .315" and .430" diameter heaters.
Insulated stranded wire crimped to cold pin. Crimp connection is insulated with fiberglass sleeving. Available for .260", .315" and .430" diameter heaters. Wire insulation rated to 250°C, 450°C optional. Specify lead length.
FLEXIBLE ARMOUR CABLE:
Stainless Steel Wire Over braid Provides excellent protection to lead wires against abrasion and contaminants. Available for .260", .315" and .430" diameter heaters. Specify cable and lead length. Style may vary from depiction depending on heater diameter and cable diameter used.