Heating Elements

Carlton Technologies are one of the market leaders in design and manufacture of electric heating elements for the OEM and distribution markets. Heating elements are manufactured in many different shapes and sizes dependant on the application and material to be heated, elements are developed in three or four basic groups with many different styles:-

Tubular heating elements:

The heating element is basically a nickel wire inside a metal tube insulated by MGO powder. The metal tube is typically stainless steel, incolloy, titanium. The diameter can vary from 6.25mm to 16mm, Carlton are one of the only companies in the world with the knowledge and equipment to manufacture heating elements to 16mm diameter. Typical applications for tubular type are fryer elements, grill elements, hot cupboard, immersion heaters elements, defrost heating elements and heating elements for the traction market (rail rolling stock)

Cartridge heating elements:

This type of element is very similar to the tubular type of but has both the connections at one end of the steel tube. This type of element is used typically in plastic injection moulding machines, catering equipment and photographic applications. They can also be used in evaporation trays, to evaporate water which has been melted of the refrigerator/ freezing condensing unit.

Foil heating elements:

Foil type of heating or etched foil heating elements are manufactured by a process of etching away all the track, with the exception of the heating track which is required. This type of heating element is very thin only around 1.5mm in total thickness; the power can be concentrated in defined areas to suit the application. Typical applications are trouser press, catering equipment, refrigeration, rail and satellites.

Towel rail heating elements:

These are designed for duel fuel use (conventional central heating use in winter and electric towel warming facility in summer). However it can be electric only when there is no central heating system present or in new builds which are tending not have gas supplies. The elements are fully protected against overheating, by means of a built in internal pre-set thermal safety cut out and a thermal fuse.
A thermostatic version is available. This unit has a heating element with a external control box used to control ambient room temperature..
The elements vary in ratings from 150W to 800W.

Industrial and domestic immersion heaters:

Industrial water immersion heaters constructed from incoloy-800 element sheaths, 2_ BSP brass screwed head, IP65 protected terminal box, a PG16 compression cable gland, 230/400V 1 or 3 phase connections, they are supplied with a control thermostat, two thermostat/cut out pockets, 5 years warranty. Carlton hold extension stocks from 2KW to 18KW for immediate ex-stock delivery.

Domestic immersion heaters are all 3kW at 230V rated. They have a BEAB approved element and thermostat with either copper or incoloy element sheaths. Carlton hold stock of both 11" and 27". The head is industry standard 2 _" BSP brass screwed head and joint gasket, a re-settable control thermostat included and a one year warranty.

Refrigeration:

Refrigeration elements are used in units such as refrigerated counters for supermarkets as well as no frost refrigerators. The defrosting elements are supplied complete with earth connection, which is provided with or without a ground lead if this is necessary. The electrical properties of these products use the most appropriate sheath materials and provision of connections protected by vulcanizing in materials such as Silicone, Neoprene and Hypalon. As well as providing our standard model with the 'double exit', we also provide a monotube version that has connections at the same end so that fitting and wiring is possible.
No frost foils is a flexible sheet that is perfect for applications where the key needs are easy installation and uniform temperature distribution. These are mainly used in refrigerated counters for confectionary shops and ice cream show cases.
Anti-condensation cables are insulated for a maximum working temperature of 65C. To prevent any damage to the insulation protecting the wire with metal sheath or braid may be worthwhile.

Plastics:

Cartridge heaters of a high density are particularly suitable for mould heating within the plastics industry.
A ring heater is an element that can endure power densities of up to 9W/cm_ and a maximum working temperature of 350C. The outer armouring is made up of stainless steel because this protects against the risk of residues of plastics and humidity.

Listed below are some of the applications areas, we at Carlton technologies supply heating elements:-

Catering equipment Water heating
Fryer Units Vending machines
Grill units Towel rails
Plastic machines Panel heaters
Trouser press Pressure hot water systems
Refrigeration units Rail rolling stock
Rail catering equipment Rail point heating

Manufacturing Process

The manufacturing process for heating elements approximately 20 different process, from manufacture of the outer tube, nickel internal heating wire, inserting the nickel wire into the tube and filling with MGO. The tube is then swaged through a 10 ton press to compact the MGO in the tube. To reduce the stresses in the heating element the heaters are fed through a furnace to anneal the outer tube and ensure the internal MGO is dry. The heating elements are then cooled and fitted with hermetic seals to prevent moisture entering the completed heating element.

The heating element is then bent via CAD bending machine, Carlton operate a 100 % test all our production for earth leakage, flash test and continuity. The wattage tolerance is typically +/- 5% of the defined power of the heating element at design.

Carlton Technologies are enthusiastic to work with existing and new customers on standard heater projects or develop new designs and assemblies.
Carlton Technologies are please to advise of a new product area, complete boiler and steam generator assemblies, either bespoke design to the customer requirements or from our standard designs. Generally this range of product is a stainless steel tank supplied complete with heating element, water inlet and outlet.