Industrial Heater Innovation: DHE Cuts Energy Use and Cycle Time in Automotive Production

When it comes to the plastics and automobile components industry, time is money. A couple of seconds in an injection moulding heater cycle or a minor spike in barrel temperature can translate to thousands of spoiled parts and hours of lost production. That’s precisely the problem that a Tier-1 automotive parts supplier in India was facing.  This was before their approach to DHE Heaters, a reputed industrial heater manufacturer in India, which offered them the best industrial heating element, which in turn helped them turn their business around. 

Here’s a peek into behind the scenes of how DHE, the best cartridge heater supplier and band heater with thermocouple expert, collaborated with the client to redesign their heating system.
The outcome was difficult to ignore!  Cycle times reduced by over 11%, energy consumption decreased by nearly 15%, scrap decreased by 22%, and heater life doubled.

If you are seeking similar problems and need optimal results, Speak to a DHE Engineer Today

The Problem: Heat Inconsistency in Injection Molding

The client was running eight injection moulding presses around the clock. But despite heavy investment in machinery, they struggled with unstable heating:
  • Barrel heaters fluctuated by ±6 °C.
  • Scrap rates reached over 5%.
  • Cycle times stuck at 41.2 seconds.
  • Heaters failed every 5–6 months.
  • Energy use climbed to 3.9 kWh per 100 parts.

They required more than replacement parts. They required an India-based partner-level industrial heater company that could audit, design, and provide customized injection molding heaters for long-term impact.

Why They Chose DHE Heaters

DHE was the best because of:
  • Established reputation as an industrial heater company in India
  • Specialization as a cartridge heater supplier with high-density swaged designs.
  • Consistent band heaters with thermocouples for tighter control.
  • Rapid prototyping and rollout.

The best industries are saving with DHE’s leading industry heaters, and we wanted to extend this benefit to the problem at hand here as well. So here’s what we did. 

The DHE Solution

Step 1: Thermal Audit

  • Energy meters + FLIR thermal images uncovered hotspots and watt density deficiencies.

Step 2: High-Density Cartridge Heaters

  • Swaged MgO construction for extended life up to 750 °C.
  • Distributed wattage areas.
  • Exact sheath-to-bore fit.
  • Learn more about DHE’s Cartridge Heaters for industrial heating. 

Step 3: Band Heaters with Thermocouples

  • Ceramic-insulated bands for consistent heating.
  • Integrated type-K thermocouples close to the melt zone.
  • Safer handling with reduced skin temperature.

View our Band Heaters with Thermocouples for industrial heating.

Step 4: Control Optimization

  • Retuned PID loops.
  • Fit SSRs with suitable heat sinks.
  • Shielded wiring to prevent electrical noise.

Step 5: Floor-Specific Customizations

  • Moisture-resistant potting.
  • Orientation of wire exits for strain relief.
  • Fiberglass-insulated leads.

For the ideal Custom Heating Solutions, get in touch with us today!

The Results

After three months:
  • Cycle time reduced by 11.3% (41.2s → 36.6s).
  • Energy per part reduced 14.7% (3.9 → 3.3 kWh).
  • Scrap rate decreased 22.1% (5.2% → 4.0%).
  • Heater life doubled (5–6 months → 12+ months).
  • Control band reduced from ±6 °C → ±1.8 °C.
  • ROI realized within less than 5 months.

“Rejection rates decreased. Energy savings were evident from month two. ROI was a no-brainer.” – R.K., Production Head

Key Takeaways for Manufacturers

  • Generic heaters are more expensive in terms of downtime and scrap.
  • Band heaters with thermocouples provide more precise readings compared to external sensors.
  • Custom specifications (watt density, sheath, insulation) prolong heater life.
  • The appropriate cartridge heater supplier audits and engineers, and not merely ships products.

Why DHE Heaters Are Different

Each batch is checked for:
  • Insulation resistance @ 500V.
  • Hi-Pot @ 1500V.
  • Continuity + dimensional accuracy.
  • Lot-based QC traceability.

This is why manufacturers in plastics, packaging, and the automotive industry regard DHE as the premier industrial heater manufacturer in India.

The story of this auto parts supplier is evidence that when you select an industrial heater producer in India who behaves like a partner rather than simply a parts supplier, you gain genuine ROI. With cartridge heaters with high-density band heaters, with thermocouples and custom injection molding heaters, DHE Heaters saved scrap, reduced energy, and increased heater life.

Stop wasting energy. Start saving money. Talk to a DHE Engineer and transform inefficiency into measurable gains.

Product Enquiry