Discover how a leading industrial heater manufacturer in India resolved manifold thermal instability by improving heat transfer efficiency, reducing downtime, and restoring stable production performance.
Trouble rarely trips, clattering into an industrial heating application. It sneaks in as inefficiency: a few extra degrees here, a flow that isn’t quite even there, a heater due for replacement sooner than expected.
The problem, for a high-output plastic processing outfit using multi-cavity hot runner systems, persisted yet remained nebulous in nature: temperature zones inside the manifold were not matching up, energy bills inched upwards, heaters swapped more often, and production stability was being nibbled away.
It didn’t need more power.
What they needed was better heat transfer.
As a leading manufacturer of industrial heaters in India, DHE Heaters was contracted to analyse this system, not simply to provide a replacement part but to identify the root cause.
First, blame had fallen on watt density and heating capacity, but the company’s engineers at DHE uncovered something far more basic.
The rigid manifold heaters were not in proper contact with the groove channels. There was a minute air gap between the heater sheath and the groove wall. Those gaps acted as thermal barriers.
Air is an insulator.
Poor contact means poor conduction.
Operators tried to cope, but kept cranking up temperatures, which resulted in:
The fault was in geometry, not electrical power.
The manufacturer needed to:
Quite simply, a heater that’s designed for groove conformity, not dimensional fit.
That’s where the engineering-first approach of DHE’s leading industrial heaters came into play. Learn how DHE is preparing for 2026 and what every plastics manufacturer must understand about smarter heating in our detailed guide: Smarter Heating Will Matter More in 2026.
Instead of increasing watt density or changing power configuration, DHE experts suggested replacing in its Flexible Manifold Heater.
Guiding principle: the contact efficiency defines performance in groove-based heating.
This heater is designed to compress into the recessed manifold grooves, and it ensures full surface contact along the heating channel.
This is not possible with rigid parts-they cannot adapt to minor geometry variations in the groove.
Key features:
This flexibility removes any air gaps and considerably enhances the heat transfer from the sheath to the manifold.
The system felt different right away after installing the Flexible Manifold Heater.
Huge contraction in the temperature difference across zones: Infrared thermal maps showed much uniformity-smoother flow.
With better heat transfer, operators didn’t have to push the power higher to compensate. Energy use levelled out.
Reduced hotspots and an improved surface contact reduce thermal stress for an extended life.
This flexible design made installation easier and resulted in consistent groove seating. Changeovers became faster and more predictable.
Steadier manifold heating translated to better control of the melt, less scraps, and fewer process interruptions.
As a leading industrial heater manufacturer in India, DHE focuses on application-specific engineering that improves heat transfer, production stability, and long-term efficiency. Connect with our team to evaluate your current heating setup and identify opportunities for smarter, more reliable performance.
Being one of the leading Indian industrial heaters manufacturers is not merely about size; it is about solving real application challenges with precision.
Quick fixes have been the treatment for many failures: more power, different wiring, swapping in a similar heater. But that doesn’t address geometric mismatch or conduction inefficiencies.
DHE dug into the root cause. The answer wasn’t more heat. It was better heat transfer.
That’s the line between a component supplier and a true thermal solutions partner.
Basically, there are three pillars on which heating efficiency rests.
This is due to its chrome-nickel steel construction that withstands demanding environments.
By matching heater design to manifold geometry, DHE restored process stability without adding operational stress.
The payoff went way beyond immediate temperature tuning:
In high-volume plastic processing, small gains in heat stability add up over time. It is a good example of how sound engineering can improve both the technical performance and economic aspects of operations.
Most industrial heating problems appear to be complicated, yet actually they are caused by minor mismatches in design. By diagnosing the problem of groove contact and deploying the Flexible Manifold Heater, DHE reiterated its position as one of the major Indian industrial heater manufacturers that believe in engineering precision rather than quick fixes.
Heat transfer isn’t only about power. It’s all about contact, stability, and system alignment. When these come into alignment, performance results.
If your heating system is underperforming, don’t settle for temporary adjustments or higher wattage fixes. Partner with a team that understands the science behind thermal performance. As a leading industrial heater manufacturer in India, DHE delivers engineered solutions designed for precision, efficiency, and long-term reliability. Speak with our experts today and redefine how your heating system performs.
Rigid heaters are not able to contact the surface fully and therefore provide air gaps that cut heat transfer and cause localised overheating.
It compresses into the groove, giving better surface contact and more uniform heat distribution.
Chrome nickel steel is used for durability and thermal stability.
Nominal sizes include 6.5 mm and 8.5 mm.
Because it focuses on application-specific engineering solutions to better system performance, efficiency, and long-term reliability.
Survey No. 687/1, Hirapur Cross Road, Mahemdavad Highway, Hirapur-Barejadi Road, Ahmedabad – 382435
