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Elmec Speciality High Watt Density Cartridge Heaters are manufactured with most advanced technology and quality raw materials, enables usage with high watts in small spaces and advanced manufacturing process ensures our heaters are vibration proof and thus ensures excellent reliability in heavy duty working conditions (Like Plastic Processing, Printing, Packaging and automobile industries where the heaters are subjected to heavy vibrations). The high performance is achieved by correct installation of the cartridge heaters. The perfect fitness of the heater in the hole facilitates good heat exchange between the surfaces of heater and mass to be heated thus increases the heater life and reduces energy loss 


  • High watt density cartridge heaters make it possible to have high watts in less space without sacrificing life time.
  • Proof against shock and vibration.
  • Excellent heat transfer.
  • Maximum operating temperature 1400o F (750o C) on heater surface.
  • Our heaters are cylindrically ground to have better surface contact and minimum hole tolerance.
  • Leak proof Tig welded end cap prevents heater contamination due to the entry of any foreign materials.


  • Sheathing material : SS 304 & SS 316 & Incoloy.
  • Available with inbuilt Thermocouple 'J' or 'K'.
  • Maximum sheath temperature 800oC.
  • Rugged & durable construction.
  • Highly compacted construction improves heater life and reduces the effect of vibration and shock.
  • Excellent heat transfer.


  • Plastic Processing Machinery.
  • Injection Moulding Machine
  • Blow Moulding Machine
  • Plastic Extruder & Extrusion Dies
  • Hot Runner Moulds.
  • Hot Stamping.
  • Food processing machinery.
  • Medical Equipment
  • Packaging machinery.
  • Lead melting for battery industries & die casting
  • Shoe Machinery
  • Packaging Equipment
  • Moulds & Dies
  • Rubber Industry
  • Chemical Industry
  • Heating Liquids
  • Power Plants
  • Automobile Industries and many more applications

High Watt Density Cartridge Heaters with Built-in Thermocouple

Cartridge heaters can be produced with built in ‘J’ or ‘K’ type thermocouples to provide heat control to increase heater life and to save energy


Junction at the bottom, ungrounded suitable to avoid disturbance to sensitive controllers.


  Junction at center gives faster response. The control of the heat transfer in the application is possible.



Type of Thermocouple

Code Positive Colour Negative Colour Temperature Range
J Iron (+) White Constantan (-) Red -20°C to + 750°C
K Chromel (+) Yellow Alumel (-) Red -20°C to + 1260°C



Mounting Bore Clearance

Watt Density VS Fit Size for Cartridge Heaters

Operating temperature of heater and fit size are major factors in determining the life expectancy of cartridge heaters. Select closest possible fit size for installing cartridge heaters for heating metal parts below

Hole Tolerance

  • < 80mm length + 0.1 mm
  • 81 to 200mm length + 0.15mm
  • > 201 mm length + 0.2mm
  • Hole tolerance H7 up to 20W/Sq.cm
  • For higher load press fitting is required
  • Fit = Max.hole diameter – Min.heater diameter


  • Heater Dia 15.8 (Maximum Tolerance – 0.08mm)
  • Hole Dia 15.9
  • Clearance 15.9 – 15.72 (15.8-0.08mm=15.72)

                                                   = 0.18mm

  • We recommend tightest possible fit.
Refer Operating temperature Vs Watt density graph to
find max permissible clearance.                                                                                                                          
Dia mm  3  5 6.5 8 10 12.5 16 20 22 25
inch  1/8  3/16  1/4 5/16 3/8 1/2 5/8 3/4 7/8 1



Sheath Material                                            Cr Ni-Steel
Insulation Material Mgo
Resistance Wire Ni Cr 80-20
Maximum Sheath Temperature 700°C
Die Electrical Strength 800V A/C
Insulation > 5 M W
Thermocouple J type (Standard) or K type
Length Tolerance (Straight) + 5%
Wattage Tolerance + 10% (+ 5% Available Upon Request)
Resistance Tolerance + 10% (+ 5% Available Upon Request)
Unheated Length 35mm (Standard)
Dimensional Tolerance Coil I.D + 0.1 to 0.2mm
Coil Length + 1mm


When Ordering please Specify

  • Dia & length of the heater.
  • Wattage and voltage.
  • Type of terminal.
  • Drawing for special type configuration.

We can manufacture and supply any intermediate diameter and length, Send drawing or sample for special size.


  • Fibre glass or Teflon wire crimped or welded to terminals.
  • Fibre glass wire with SS metal braiding.
  • Wires protected with SS or GI flexible conduits.
  • All wires are available in straight or right angle exit.
  • Drawing or sample required for special type terminals.


Fiber Glass Sleeve

Metal Braid Flexible Metal Armour