
Edge Wound Heaters: The Key to Consistent and Reliable Industrial Heating Solutions
Introduction
Edge wound heaters are a fundamental component in industrial heating systems, renowned for their efficiency and reliability. These specialized heaters play a crucial role in various industries, offering consistent and precise heating solutions. Understanding their construction, technical specifications, benefits, and applications sheds light on their significance in modern industrial processes.
Construction of Edge Wound Heaters
Marathon heater manufacture specially design and develop edge wound heaters, which are also known as bayonet heaters. Edge wound elements are used in applications where utmost power is required in limited space. These elements replace rod elements in furnaces requiring more power and are used to convert gas-fired furnaces to electric heating.
Edge wound heaters are meticulously constructed using high-quality resistance wires wound in a helical manner along the edges of a ceramic insulator. This unique design ensures uniform heat distribution, maximizing heating efficiency and longevity. The construction allows for tailored configurations to meet specific heating requirements, making them versatile for diverse industrial applications.
Different furnaces, such as roller hearth, pit, batch, low-temperature aluminum tempering furnaces, and high-temperature exothermic gas generators, use these heating elements to meet their heating requirements.
1. Heating element: Nichrome 80:20, Ferritic alloys mara FeCrAl
2. Diameter up to 160 mm
3. High-resistance strip of edge bending in coil form which is wound on high aluminium ceramic bobbins.

Technical Specifications and Features of Marathon Edge Wound Heaters
- Voltage Rating: customizable according to application needs.
- Wattage: 65 kW
- Temperature Range: Up to 1950°F (1050°C)
- Durability: Robust construction for long-lasting performance in harsh industrial environments.
- Length: Customizable
- Fast Response Time: Rapid heating and cooling cycles for efficient operation.
Features of edge wound heaters
- Higher power density
- Easy to install, replace and install
- Long service life at all temperatures
- Horizontal or vertical mounting
- Repairable to extend service life
Benefits of Edge Wound Heaters
Edge wound heaters offer several advantages that make them a preferred choice in various industrial applications:
Precision Heating:
Edge wound heaters are designed to provide precise and consistent temperature control. This level of accuracy is crucial in industrial processes where maintaining specific temperatures is essential for product quality and process efficiency. By ensuring accurate heating, these heaters contribute to improved overall performance.
Energy Efficiency:
These heaters are known for their optimal heat transfer capabilities. By efficiently transferring heat to the target area, they help minimize energy consumption. This increased energy efficiency not only reduces operational costs but also aligns with sustainability goals by lowering overall energy usage.
Longevity:
Edge wound heaters are built using durable construction and high-quality materials. This robust design ensures a longer lifespan for the heaters, reducing the frequency of replacements and maintenance. This longevity translates to cost savings in the long run and less downtime due to equipment failure.
Versatility:
One of the key advantages of edge wound heaters is their customizable designs. This flexibility allows them to be tailored to various heating applications, making them suitable for a wide range of industrial processes. Whether it’s for heating liquids, gases, or solids, these heaters can be adapted to meet specific requirements.
Safety:
Edge wound heaters often come with built-in safety features that enhance operational security. These features help prevent overheating, electrical malfunctions, and other potential hazards, ensuring a safe working environment. Additionally, their reliable performance further contributes to operational safety by minimizing the risk of unexpected failures.
Heat Distribution:
The helical winding pattern of the resistance wire along the edges of the insulator promotes even heat distribution across the entire surface area. This uniform heating ensures consistent temperatures throughout the heating process, crucial for applications requiring precise thermal control.
Customization Options:
Manufacturers offer a wide range of customization options for Edge Wound Heaters, including variations in size, shape, watt density, voltage ratings, and temperature ranges. This flexibility allows for tailored solutions that meet specific heating requirements in various industries.
Temperature Control:
Edge Wound Heaters excel in providing accurate temperature control, crucial for processes where precise heating is essential. Their ability to reach high temperatures while maintaining stability makes them ideal for demanding industrial applications.
Thermal Efficiency:
These heaters are designed for optimal thermal efficiency, ensuring maximum heat transfer to the target area. This efficiency not only reduces energy consumption but also enhances the overall performance of industrial processes.
Reliability:
These heaters are known for their reliability and durability. Built to withstand harsh operating conditions, they offer long-term performance with minimal maintenance requirements, contributing to cost savings and operational efficiency.
Safety Features:
Many Edge Wound Heaters come equipped with safety features such as overheat protection and insulation to prevent accidents and ensure safe operation in industrial settings.
Environmental Considerations:
These heaters are designed with environmental considerations in mind, using materials that are safe and sustainable. Their energy-efficient operation also contributes to reducing carbon footprints in industrial processes.
Applications in Various Industries
These heaters find extensive use across diverse industries, including:
- Plastic and Rubber Processing: Mold heating, extrusion processes.
- Packaging: Heat sealing, shrink wrapping.
- Food Processing: Oven and cooking equipment.
- Semiconductor Manufacturing: Wafer processing, vacuum chambers.
- Aerospace: Composite curing, de-icing systems.
- Medical: Sterilization equipment, diagnostic devices.
- Annealing furnace
- Spherodizing furnace
- Heat treatment furnaces
Conclusion
Edge Wound Heaters represent a cornerstone in industrial heating technology, offering unparalleled efficiency, reliability, and versatility. Their precise construction, technical features, and numerous benefits make them indispensable in a wide array of industrial applications. Embracing these advanced heating solutions ensures consistent performance, energy savings, and enhanced productivity in today’s demanding industrial landscape.
These heaters represent a cutting-edge solution in industrial heating technology, offering a combination of precision, efficiency, reliability, and flexibility.
Explore more about process heaters at Marathon Heater and experience the innovation driving heating and sensing technologies forward.
Contact us at enquiry@marathonheat.com for your requirement of circulation heaters or any other industrial heater.