Energy Savings

Save Up To 70% In Energy Costs

The TCS System Infrared heating elements generate radiant energy, which is faster-acting and more efficient than conductive heat. The infrared heater elements reach their typical operating temperature of 1100 F in 15 sec.

The heater elements are embedded in the underside of sections of vacuum-cast ceramic-fiber insulation, which reduces heat escape to the plant floor, thereby increasing worker comfort and reducing the cost of plant air conditioning. While operating, the outside of the insulation is just warm to the touch. The TCS System insulated heater modules cover 100% of the barrel’s surface (unlike standard heaters). Prewired sections are held together by stainless steel, Velcro-style fasteners. (Unlike with heater bands, processors need not be concerned about obtaining a tight fit around the barrel to prevent heater burnout.)

The TCS System IR elements are offset from the barrel by 0.375 in. to leave space for vacuum cooling. An optional vacuum ring can be placed between each heating module. Each TCS System module constitutes a temperature zone that can have its own cooling-air inlets and outlets. Testing with closed-loop heating-cooling controls indicated barrel-temperature variation held within 1° F.

Energy Savings

Save Up To 70% In Energy Costs

The energy efficiency of the TCS System is around 90%, versus about 50% for most traditional heater bands. As a result, typical energy savings with the TCS System range from 50% to 70%. This is due to both the infrared heating and insulation as well as the rapid ramp-up and ramp-down, which cuts the time heaters need to be operating. Moreover, heat distribution in the barrel is claimed to be more uniform and consistent than with heater bands, resulting in fewer hot and cold spots.

Faster Response Times

Unlike typical ceramic heater bands and aluminium-finned cast water cooled heaters that must first heat themselves before conducting heat into the barrels, the TCS System heaters transfer heat immediately giving you up to 55% faster heat up times, which translates directly to increased productivity.

Operating costs are lower with the TCS System due to energy savings and longer service life, estimated at five years vs. one to two years for heater bands. Payback on investment is put at 12 to 18 months.

Tighter Temperature Control

The TCS System’s direct radiant heating and direct air cooling results in faster response to changing barrel conditions, reducing overshoot and heat transfer lag time resulting in tighter temperature control even at very high operating temperatures. Temperature control is +/-1 °F. Tighter control means less scrap and variability in product performance.

Maintenance Free Cooling

The TCS System has a unique air-cooling system that utilizes a specially designed blower encased in a sound absorbing housing. This quiet system draws ambient air directly across the barrel and underneath the heater giving instant cooling. The blowers are designed for start/stop operations and durability. Unlike water-cooling where corrosion is an issue, this cooling system will give you years of maintenance free operation saving you significant $$$ in maintenance cost.

Direct the Hot Air

Want to heat your plant during the winter? Want to vent the hot air during the summer? With the SERVTEK TCS System you have the option. We can save you considerable cost on your cooling or heating bills by directing the hot air to where you want it! The heat removed from the barrel passes thru the blower discharge port and can be hooked up to an exhaust or preheated system.

More Operator Comfort

Conventional heaters release as much heat into the working environment as they do into the barrel. The SERVTEK TCS System substantially reduces the amount of heat loss to your environment making it very comfortable to work around and saving you $$$ on your air conditioning cost.

Safer Operation

Since the SERVTEK TCS System has high temperature ceramic insulation, it is relatively cool compared to all other types of heaters adding a dimension of safety to your facility. . The insulation body of the heater reduces the “cold face” temperature significantly and enhances safety. An internal "hot face" temperature of 400°F, depending on plant environment, will result in a production "cold face" temperature of approximately 110°F to 115°F. You can lay your hand on the “cold face” and feel comfortable warmth---far different than the Mica, Cast, or Ceramic Bead heaters sold in the market today. Also, the electrical connections are all recessed. Safety from burning or exposed electrical connections is dramatically improved through design wire exposure.

Simplicity

The SERVTEK TCS System is very simple to install and remove. Its unique design has the heating sections strapped together with high-quality Velcro. Just undo the Velcro and wrap the heater around the barrel and you are ready to hook it up. It is just that easy!

Reduce Spare Parts Inventory

The SERVTEK TCS System is designed to operate at much higher temperatures than those found in plastic processing and utilize proven industrial heater technology, which translates to extremely long life. Each band heater assembly consists of a series of segmented heaters wired together in series so if one section does have a problem, all you have to do is replace that section. Your inventory of heaters will go down to a few heater sections. With SERVTEK’s quick turn around times, heater sections can be shipped within days so the need for stocking lots of parts on the shelf is over!