Save Money on Industrial Air Heaters

Posted by Sam Pelonis | Oct 26, 2015 1:00:00 PM | 0 Comments

The industrial heating of air and water can be expensive. But you can effectively heat both air and water for industrial applications without breaking the bank. In fact, energy experts at the U.S. Department of Energy (DOE) found that it is possible to save millions of dollars in industrial settings, such as energy-intensive manufacturing plants, simply by improving the energy efficiency of steam or process heating systems. To save money on the industrial heating of air and water, be sure to keep the following in mind.

Use proper furnace insulation techniquesUse proper furnace insulation techniques. Simply by properly insulating furnaces, a major industrial plant can potentially save 1 million MMBtu of natural gas per year, according to energy-efficiency specialists in the DOE Industrial Technologies Program (ITP). That translates into a monetary savings of close to $12 million annually, as well as annual carbon dioxide savings of 124,000 metric tons. Proper insulation of the furnace also prolongs operating life. How can you ensure that your furnace is properly insulated?

• First, make sure to check heat transfer surfaces. Particularly for industrial process heating systems, making sure heat transfer surfaces are free from any kind of soot, scale, or oxide deposits will significantly improve system efficiency. Also, be sure to monitor conditions that could produce deposits on heat transfer surfaces, including low air to fuel ratios, poor fuel preparation, malfunctioning burners, and corrosive gases or constituents in the heating medium. 

• Second, you will want to reduce air infiltration in furnaces. Air leakage into the furnace or leakage of flue gases from the furnace into the ambient air can occur via any kind of cracks or openings around the doors, joints, and hearth seals. Properly insulating your furnace means sealing up these small openings. Even the smallest crack can have an effect on efficiency, driving up your heating costs.

Keep insulating material from becoming wet. When insulating materials become wet, there can be a drop in voltage. Saturated or wet insulation elements lose their electrical insulation and subsequently leak voltage to the ground. As a result, this increases the overall current draw and decreases the efficiency of the furnace.

Reduce watt density. In order to maximize the performance and efficiency of a heater, it is advantageous to reduce watt density. When watt density is too high, it can cause localized overheating. If you are using a high watt density for viscous, poorly conductive, or unusually heavy fluids, you might want to consider using higher temperature protectors or de-rating heaters, as this will allow you to lower the watt density.

Choose an immersion heater. Immersion heaters offer a number of advantages, including energy efficiency. They boast an incredibly high thermal conductivity and, therefore, are significantly more efficient than other metallic and non-metallic heating elements. To save money on the industrial heating of air and water, an immersion heater is an excellent choice.

Ensure the heater guard is properly installed. Heater guards can be easily installed at the inlet or supply of any water heater, and they work to keep dirt, rust, silt, and sediment out of your water heater, ensuring that your water heater operates optimally, which saves and energy and prolongs the lifespan of your device. Proper installation of the heater guard ensures efficient heat transmission as well as improved temperature regulation.

Check the thermal conductivity of the medium being heated. The medium you are heating will significantly affect the efficiency of your heating operations. The higher the thermal conductivity of the medium, the easier it will be to heat it and the more efficient the operation will be. Always check the thermal conductivity of the medium being heated.

Ensure your water tank is properly insulated. Just like you need to properly insulate your furnace, you also need to properly insulate your water tank in order to maximize energy efficiency. Proper insulation can actually reduce standby heat losses by up to 45 percent, which translates into monetary savings of up to 9 percent on your heating bill.

Our eBook, the Design Process of Industrial Heating Systems, can give you additional insight into how industrial heating contirbutes to cost-effective operations measures within companies and organization. Click below to get a copy.

Design Process  of Industrial Heating Systems Download eBook >Contact us today find the industrial heating solution that works with your budget and gets you the results you need.


Custom DC Fans for the Medical Industry

Posted by Sam Pelonis | Jul 20, 2015 4:29:00 PM | 0 Comments

In the medical industry, heart monitors are commonly used in patient care. These precision devices are recognized for the notable benefits they provide.

The use of heart monitors enables healthcare practitioners to recognize heart irregularities a patient may have. With this constant monitoring, practitioners can quickly attend to any potentially life-threatening issues.

dc-fanPreventative medical care has become progressively more demanding, and as such, devices like heart monitors must provide higher levels of performance. Unfortunately, improving the performance of a medical device does not necessarily improve its reliability.

At Pelonis Technologies, we have manufactured heating and cooling custom solutions for many years—and these solutions are frequently used to deliver enhanced reliability to medical applications. The case study below documents our manufacturing of a DC brushless fan for use in the medical industry.


A medical company came to Pelonis needing a specialized, high-efficiency DC fan. This fan was to be used to cool the system componentry of a heart monitor machine. In addition to providing adequate cooling, the fan needed a variable air flow speed and custom wire connections and labeling.


Our engineering team designed an 80x80x15mm DC fan capable of operating at 48 volts. Along with the client’s distinct specifications, we utilized 2D CAD drawings to conceptualize the product.

The manufactured DC fan was tested meticulously for proper airflow, static pressure, speed, and power. Additionally, the DC fan passed dimensional and functionality inspections.


With a short turnaround of 12 weeks, Pelonis delivered the new fan directly to the client’s door. Our DC fan offered an exceptional air efficiency of 40.7 cubic feet per minute (CFM) and a water pressure of 0.020 inches. The DC brushless fan was also fitted with Pulse Width Modulation to control the fan’s speed manually.

Heat management is a key concern of medical device users. Pelonis’ extensive industrial experience was instrumental in not only meeting, but exceeding the expectations of this medical company. For more information about the cooling fans available for your industry or application, download our eBook, How to Select a Cooling Fan.

Download How to Select a Cooling Fan

There is no room for error when manufacturing products for medical applications. If your company needs a custom solution, please contact Pelonis Technologies today. 


High Temp Ceramic Immersion Heater | Pelonis Tech

Posted by Sam Pelonis | Jul 13, 2015 9:55:00 AM | 2 Comments

Industrial and commercial heating applications are considerably demanding. Though there are many options to choose from, heating solutions often fall short of consumer expectations. Today, it’s not enough to simply meet application requirements—you should strive to exceed them.

Advancements in heat technology have facilitated the creation of highly efficient and versatile products—these products are better suited for modern heating. As a leading manufacturer of specialized heating products, Pelonis Technologies is proud to announce our latest innovation: Ultra-High Temperature Ceramic Immersion Heaters.

immersion-heatersOur immersion heaters are designed to accommodate several applications, which include: central heating systems, steam generation, ignition devices, solar heater support, and much more. These heaters boast higher efficiency and thermal conductivity as compared to other heating elements (either metallic or non-metallic).

Performance of Immersion Heaters

Ultra-High Temperature Ceramic Immersion Heaters are versatile enough for use in both air and underwater. In dry environments, these products are capable of heating up to 1200°C (2192°F); underwater, they can reach up to 98% heating efficiency. These ceramic heating elements are very compact and can be installed into small devices with little effort.

Immersion heaters are completely self-regulating and have desirable insulation properties; this affords the ability to withstand voltages of 2500 volts as well as corrosive, acidic conditions. Additionally, our immersion heaters are safe to use, and do not negatively affect the environment.

Our Solutions:

Regardless of the location, immersion heaters deliver superior performance. Pelonis’ line of immersion heaters features K Series and KC Series products.

k-series-immersion-heaterK Series Ultra-High Temperature Ceramic Immersion Heaters have the following operating specifications:

  • Thicknesses of 4mm
  • Rated voltages ranging from 110Vto 220V
  • Rated power in Water: 210W to 1500W
  • Rated Power in Air: 100W to 600W
  • Temperature range in Air: 400°C (752°F) to > 1200°C

kc-series-immersion-heaterKC Series Ultra-High Temperature Ceramic Immersion Heaters include:

  • Thicknesses of 4mm
  • Rated voltages ranging from 110Vto 220V
  • Rated power in Water: 500W to 3000W
  • Rated Power in Air: 220W to 360W
  • Temperature range in Air: 650°C (1202°F) to 1200°C

Choose an Immersion Heater Today

PTI’s immersion heaters are lightweight, compact, and provide high efficiency and safety to any application. These heaters are resilient enough to ensure long, trouble-free operation.

Download Our Electronics Cooling eBook

Please visit Pelonis Technologies’ Immersion Heater Page for more information, and be sure to peruse our product catalog. If you have any questions pertaining to any of our heating solutions, feel free to contact us.