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What Is the Difference Between Mica Band Heaters and Ceramic Band Heaters?

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Thermal Corporation infographic explaining the differences between mica band heaters and ceramic band heaters

Home > Blog Archive > Category: Industrial Heating Technology > What Is the Difference Between Mica Band Heaters and Ceramic Band Heaters?

 

The Differences Between Band Heaters: Mica Bands vs Ceramic Bands

 

There are two types of band heaters that Thermal Corporation manufactures: mica band heaters and ceramic band heaters. There are strong points with each type, and the general differences are laid out below:

Temperatures

Ceramic band heaters can withstand a higher temperature than mica band heaters. Ceramic band heaters have a maximum operating temperature of 1200⁰F vs a maximum operating temperature of 800⁰F for a mica band heater.

Heater Life

Ceramic band heaters typically (but not always) have a longer life expectancy. This is due to the coiled resistance wire that is fed through ceramic blocks (called knuckles) vs. the thin resistance ribbon that is used in mica band heaters. The coiled resistance wire has a smaller ratio of surface area to internal cross-sectional area and thus doesn’t really oxidize and burn through as fast as the ribbon.

Watt Density

Mica band heaters can have a higher watt density than ceramic band heaters. Because the resistance ribbon in a mica band heater is tightly clamped between pieces of mica, there is better heat transfer from the ribbon to the exterior surfaces of the heater. Also, in general, mica band heaters will have less unheated area than a ceramic band heater, especially in smaller band heaters.

Customizability

Mica sheets can be cut into custom shapes and sizes, whereas ceramic band heaters are limited by the size of the knuckles. Because of this, mica band heaters are also much more customizable when it comes to dimensions. Ceramic band heaters are limited to 1/2″ width increments, whereas mica band heaters can be any width within the upper and lower limits of at least 1″ by 1″, depending on the specific mica band configuration.

Pricing

Ceramic band heaters are more expensive than mica bands. The ceramic knuckles are quite expensive when compared to the thin sheets of mica that mica bands are constructed from. However, this difference may be compensated for by the increased efficiency of the ceramic band heater.

Insulation Options

Standard ceramic band heaters have one layer of 3/8″ thick ceramic paper insulation over the knuckles, and then a stainless-steel outer sheath that reflects heat back into the process. The “Heat Saver” ceramic band insulation option has one layer of 1/8″ thick ceramic paper topped with a reflective stainless-steel sheath, and then an additional 2 layers of 3/8″ thick paper, topped by an additional sheath. All of this insulation yields a higher efficiency heater vs. a mica band heater. Ceramic band heaters also offer a “Vented Outer Sheath” option, seen in the image below. This allows heat to escape from the process, if needed for your application.

Closing Remarks

In conclusion, you just need to examine your heating process and specific needs for a band heater and decide between a mica band heater or a ceramic band heater. If we can be of any assistance, please let us know. Mica bands are cheaper, can have higher watt density, and are more easily customizable. Ceramic bands are more efficient, can withstand higher temperature, and generally last longer.

 

Have Questions?

Contact our engineers at (800) 633-2962 x152, or by email at engineering@thermalcorp.com.

 

Written by Kyle Otte
Edited by Shelby Reece
Date Published: 01.14.2020
Last Updated: 01.14.2020

 

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made in usa

Reputation

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Home > Blog Archive > Category: Inspirational Quotes > Reputation

Reputation

You can’t build a reputation on what you are going to do. – Henry Ford

Recently, Thermal Corporation has been working hard to improve the way we are seen by our customers and by other heater manufacturing companies. When we came across this quote by Henry Ford, it reminded us of our efforts to build upon our already established reputation of being the best manufacturer with the fastest shipping of standard and custom industrial heaters in the United States.

We have achieved this reputation through the hard work of our family of employees. Not only the customer service representatives who work with you daily, but our engineers, managers, technicians, manufacturing fabricators, quality control, purchasing, inventory, and shipping specialists, as well as, the systems administrator, sales and marketing, and our management team. We could not achieve this amazing status without every single one of them. But, like Henry Ford said, “You can’t build a reputation on what you are going to do.” Meaning, you build a reputation on what you actually DO! Our founder, Mr. Bob Stottle, began Thermal Corporation fifty years ago in 1969. Thermal Corporation’s reputation was built upon the ideas of Mr. Stottle and it continues because of everyone who helps keep our company strong after all of these years.

Our Promise to You

To continue working hard to maintain our reputation of…

  • Exceptional customer service
  • Fast shipping
  • Prompt troubleshooting
  • Rapid response time

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AND most of all…

  • Quality products

…manufactured right here in the United States to keep your heating processes running successfully and efficiently on a daily basis!

Have a custom request or need advice on a heating process?

Contact us instantly by using the chat feature located at the bottom right of the page. Visit our contact page for more information on how to get in touch with us!

Written by Shelby Reece
Edited by TC Marketing Team
Date Published: 07.30.2019
Last Updated: 08.26.2019

bob

A Dream Come True

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Home > Blog Archive > Category: Inspirational Quotes > A Dream Come True

A Dream Come True

CELEBRATING 50 YEARS, and Looking Forward to 50 MORE YEARS

All our dreams can come true, if we have the courage to pursue them. – Walt Disney

History of Thermal Corporation

For those of you who have not had the chance to read the history behind Thermal Corporation and how we got started, here is a brief overview:

Bob Stottle, the founder of Thermal Corporation

Thermal Corporation got its start in 1969, by a man named Bob Stottle, as a catalog-house and distributor of thermal supplies. The orders were few at the time and Mr. Stottle felt like he might have to find part-time work. Then, a sales representative, from a company that supplied cartridge heaters and band heaters to the plastics industry, visited Mr. Stottle. Soon after the meeting, business began to soar as Thermal Corporation got into the industrial heater market.

Within six years, Thermal Corporation became the largest distributor of band and cartridge heaters for the biggest manufacturer of those products in the United States. Customers soon began requesting temperature sensors. So in 1977, Mr. Stottle made the decision to add thermocouple probes to our product line. Because Mr. Stottle could not find a reliable producer of these products, he decided to produce them in-house. This marked the beginning of manufacturing at Thermal Corporation.

Over the years, Thermal Corporation has received much recognition for being a leader in quality and service, including the Alabama U.S. Senate Award of Excellence in Continuous Productivity and Quality Improvement. To this day, Thermal Corporation maintains our efforts of continual improvements to make sure we remain the BEST at what we do– quality heating products, competitive pricing, and the fastest shipping in the industry.

Entrepreneurs with Big Dreams

Walt Disney

As you can see from our company history, Thermal Corporation started off pretty slowly, just like the Walt Disney Company. (Learn more about the Walt Disney Company history here.) Both Walt Disney and Bob Stottle were entrepreneurs with big dreams who started off the same way.

Disney said, “All our dreams can come true, if we have the courage to pursue them.”

Mr. Stottle, an engineer working in university and industrial laboratories, had wished to provide the kind of service and products that were not available when he was an engineer working in the industry. So, he did!

Mr. Stottle made his dream a reality in the founding of Thermal Corporation.

Thermal Corporation has improved greatly throughout the fifty years that we have been in business. We adhere to those same core values that Mr. Stottle taught us back when we first began. We are as excited about our future as we are proud of our past, and we will continue to provide the best quality industrial heaters in the United States with the fastest shipping time in the industry; which makes Thermal Corporation a dream come true.

Written by Shelby Reece
Edited by Kyle Otte
Date Published: 07.22.2019
Last Updated: 07.22.2019

When Thermal Says, “Rapid Response and Quick Shipping,” We Absolutely Mean It!

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Home > Blog Archive > Category: Company News > When Thermal Says, “Rapid Response and Quick Shipping,” We Absolutely Mean It!

When Thermal Says, “Rapid Response and Quick Shipping,” We Absolutely Mean It!

Today, we would like to give recognition to Jonathan from our ceramic band heater department.

Rapid Response and Quick Shipping

Two days ago, a customer called in a rush order for a ceramic band heater. The order was entered at 10:04 A.M. Jonathan came up to us at 10:58 A.M. with the heater in hand, which had already undergone final quality check, ready to ship! When the customer was contacted and informed, he said, “You are a lifesaver.”
When Thermal Corporation says, “rapid response and quick shipping,” we absolutely mean it!

A Very Special Thank You

Thank you very much to our manufacturing manager, Earl, for releasing the order in a timely manner and a very special thank you to Jonathan for making the heater in less than an hour!

Written by Shelby Reece
Edited by TC Marketing Team
Date Published: 06.25.2019
Last Updated: 11.18.2019

Thermal Corporation advertisement for February 2019 Huntsville Madison County Chamber of Commerce Initiatives Magazine

Thermal Corporation to Appear in Huntsville/Madison County Chamber of Commerce Initiatives Magazine

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Home > Blog Archive > Category: Company News > Thermal Corporation to Appear in Huntsville/Madison County Chamber of Commerce Initiatives Magazine

Thermal Corporation Ad for February 2019 Initiatives Magazine

Initiatives Magazine

The Huntsville/Madison County Chamber of Commerce releases a monthly magazine called Initiatives. Initiatives features interesting news articles about the work in which local Huntsville/Madison County companies are involved. These news articles involve changes in Huntsville’s involvement in aerospace and technology, as well as advancements in many other industries. Initiatives also features pages in which local companies can appear to help bring awareness to their business.

In 2018, we at Thermal Corporation began to discuss how Initiatives could help bring some local awareness to our company. So in November of last year (2018), Debra Kimbrel, Ushma Singh, and Shelby Reece of the Thermal Corporation Marketing Team, sat down with Lydia Pennington, Patti Walker, and Kristy Drake from the Huntsville/Madison County Chamber of Commerce to discuss appearance in the magazine’s 2019 releases. This is the first time we have worked with the Chamber of Commerce to appear in the magazine. We are so excited to announce that Thermal Corporation will be appearing in a total of three editions of the Huntsville/Madison Chamber of Commerce Initiatives magazine in 2019!

Look for Thermal Corporation in the Initiatives February, June, and October 2019 releases!

Written by Shelby Reece
Date Published: 01.28.2019
Last Updated: 09.04.2019

diagram showing the 22 new extended ranges of cartridge heater diameters

New Cartridge Heater Sizes!

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Home > Blog Archive > Category: Company News > New Cartridge Heater Sizes!

We have NEW cartridge heater sizes available!

I hope 2018 has started with many blessings for you already! We are in the starting gate, ready to offer you some NEW SIZES in Cartridge Heaters. We now have a more complete line with 22 different diameters in Metrics and Inches. Some of these we have not been able to offer in the past, but are well equipped to handle all of your needs!

Our customer service team and engineering tech team are available for you when you have questions about ordering, or placing an order. We have already had customers taking us up on these new sizes, and we hope you will too. We try hard to please our customers and meet your needs. This is a request that customers have been making for a few years, and we have been working hard on being in this position.

We will also be offering a new Band Heater experience soon. Please keep yourself informed with our announcements.

I do hope you will take advantage of these new Cartridge Heater Sizes. Have a wonderful New YEAR!! We look forward to hearing from you.

new Thermal Corporation cartridge heater sizes diagram

Written by Jennifer Taylor
Edited by Shelby Reece
Date Published: 01.02.2018
Last Updated: 09.06.2019