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Process heating solutions

Process Heating Solutions for Industrial Applications

Caldor Heat designs and manufactures advanced process heating solutions for industrial applications where precision, reliability, and long-term operational stability are critical. Our portfolio covers both standard product ranges and fully customized OEM heating systems, engineered to integrate seamlessly into your production processes.

From heating liquids, air, and gases to maintaining stable temperatures in demanding industrial environments, Caldor Heat delivers electric process heaters that support efficient, safe, and repeatable manufacturing operations. Our solutions are developed with a strong focus on thermal performance, energy efficiency, and mechanical robustness.

Comprehensive Electric Process Heater Portfolio

Our process heating range includes:

  • Immersion heaters for tanks, baths, and reservoirs

  • Circulation heaters for controlled fluid heating in closed-loop systems

  • Tubular heaters for flexible integration into machines and assemblies

  • Duct and air heaters for process air and HVAC-related applications

All heaters are designed for continuous industrial duty and manufactured using high-quality materials suitable for aggressive media, elevated temperatures, and challenging operating conditions.

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Custom OEM & Project-Specific Engineering

Beyond standard configurations, Caldor Heat specializes in OEM and project-based heating solutions. Each system can be engineered according to your exact requirements, including:

  • Power density, wattage, and voltage

  • Sheath and housing materials

  • Mounting methods and mechanical interfaces

  • Integrated temperature sensors and safety devices

Our engineering team supports customers from early concept through final production, ensuring optimal heater selection and reliable long-term performance.

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Why Electric Process Heating with Caldor Heat

Electric process heating offers clean, controllable, and highly efficient heat delivery. Compared to fuel-fired or steam-based systems, electric heaters provide:

  • Precise temperature control

  • Rapid response and uniform heat distribution

  • Lower maintenance requirements

  • Easy integration into automated systems

Caldor Heat electric process heaters are designed to meet modern industrial demands while supporting energy optimization and production continuity.


 

Engineering Support You Can Rely On


Each solution is backed by Caldor Heat’s extensive application experience and technical know-how. We provide guidance on heater sizing, material compatibility, and system integration to ensure your process operates safely and efficiently.

Explore our process heater categories or contact our engineering team to develop a tailored electric heating solution perfectly matched to your industrial process.

TANK BUILDERS & STORAGE SYSTEM MANUFACTURERS

For tank builders and OEM integrators, Caldor Heat offers fully customizable electric heating solutions designed to integrate seamlessly into any tank size, geometry, or construction type.

Our portfolio includes:

  • Electric immersion heaters for storage tanks

  • Circulation heaters for controlled fluid heating loops

  • Duct heaters for air or vapor heating inside process systems

Each heater is engineered to match your production requirements, allowing fast customization, reliable performance, and simplified installation. Electric heating eliminates combustion-related maintenance, offering your customers a maintenance-free, long-life solution with predictable operating costs and rapid delivery aligned with your manufacturing schedule.

ASPHALT INDUSTRY

Caldor Heat designs and manufactures low-watt-density electric heating solutions specifically adapted for asphalt production and storage applications. Our immersion heaters, circulation heaters, duct heaters, fuel-oil preheaters, hot-oil heaters, and distributor truck heating systems deliver stable and uniform heat transfer for bitumen and asphalt-related processes.

These electric heating solutions provide clear operational advantages for asphalt plants, including:

  • Reduced operating and energy costs

  • Improved temperature control and product consistency

  • Lower maintenance requirements compared to fuel-fired systems

  • Extended heater service life under continuous-duty conditions

  • Cleaner operation and improved environmental sustainability

All systems are manufactured in Romania by Caldor Heat Engineering SRL, ensuring European quality standards, short lead times, and full technical traceability.

INDUSTRIAL PROCESS APPLICATIONS

Caldor Heat specializes in custom-engineered process heating systems for demanding industrial applications. Our low-watt-density electric heaters are ideal for temperature-sensitive and high-viscosity materials where controlled, uniform heat is essential.

Materials commonly heated with Caldor solutions include:

  • Asphalt and bitumen

  • Light and heavy fuel oils

  • Diesel and biodiesel

  • Glycerin and hydraulic fluids

  • Lubricating oils

  • Resins and epoxies

  • Animal fats, molasses, and other sensitive media

Depending on the process, we integrate immersion heaters, circulation heaters, and duct heaters, engineered for precise thermal control, long-term reliability, and compatibility with aggressive or viscous fluids.

Manufactured in Romania and supported by in-house engineering, Caldor Heat delivers OEM-focused, project-specific electric heating solutions tailored to your industrial process requirements.

DUCT HEATERS – AIR & GAS PROCESS HEATING

Caldor Heat electric duct heaters are designed for industrial air and gas heating applications where precise temperature control and continuous operation are required.

Typical applications include:

  • Process air heating in asphalt plants

  • Heating of combustion or ventilation air

  • Drying systems and curing tunnels

  • HVAC and industrial air handling units

  • Explosion-safe or controlled-atmosphere processes (on request)

Our duct heaters are engineered to:

  • Provide uniform airflow heating

  • Operate safely at high temperatures

  • Integrate easily into rectangular or circular ducts

  • Be customized for airflow, voltage, power, and control requirements

Each unit is designed and manufactured in Romania, ensuring fast customization, full technical support, and OEM-level integration.

Caldor Heat | Asphalt Industry – Technical Information & FAQ

Process Heating • Asphalt & Bitumen • Technical Information

Asphalt Industry Heating Solutions – Technical FAQ & Documentation

Caldor Heat designs and manufactures industrial electric heating solutions for asphalt and bitumen handling, including duct heaters, circulation heaters, immersion heaters, hot-oil / fuel-oil preheaters, and OEM-integrated systems. All solutions are manufactured in Romania to EU-quality standards and engineered for continuous-duty operation.

Duct Heaters (Air/Gas) Circulation Heaters (Closed Loop) Immersion Heaters (Tanks) Hot-Oil & Fuel-Oil Preheaters OEM / Turnkey Systems

What you gain

Electric heating benefits engineered for asphalt operations:

  • Stable viscosity and temperature uniformity
  • Lower maintenance and cleaner operation
  • Long heater life with correct watt-density selection
  • Predictable control and easy automation integration

Where it fits

Typical integration points in asphalt plants:

  • Bitumen storage and day tanks
  • Hot oil circuits and thermal fluid skids
  • Process air handling and ductwork
  • Truck loading / distributor systems (OEM)

Romania manufacturing

Designed and produced in Romania with controlled processes, traceability, and application-engineering support for OEMs and plant operators.

Product Overview (Asphalt & Bitumen)

Technical scope

Asphalt heating requires controlled thermal delivery to manage viscosity, avoid localized overheating, and sustain flow stability across storage, transfer, and process stages. Caldor Heat systems are engineered to deliver heat through direct immersion, forced circulation, and air/gas duct heating depending on the process architecture.

Heater Type Primary Function Typical Use in Asphalt Plants
Duct Heaters Heat air or gases in ducts for controlled temperature processes. Process air heating, ventilation air preheat, drying/cure air streams, enclosed process zones.
Circulation Heaters Heat fluids in closed-loop systems with controlled flow and heat exchange. Thermal oil skids, inline heating for transfer circuits, controlled heating of fuel oils.
Immersion Heaters Direct tank heating for storage or conditioning. Bitumen tanks, day tanks, service tanks, chemical baths (where applicable).
Engineering principle: Correct watt density selection is critical for viscous media such as bitumen. Caldor Heat designs for stable heat flux to protect product quality and maximize heater lifetime.

Selection Guide (Quick Engineering Checklist)

Sizing inputs

To define a heater correctly, prepare the following inputs:

Category Minimum Required Data Notes
Process Medium (bitumen/asphalt/oil/air), target temperature, start temperature Include ambient conditions and duty cycle.
Flow / Volume Tank volume or flow rate, residence time, line sizes Critical for circulation heater sizing.
Electrical Voltage, phase, maximum installed power, control concept Specify control cabinet or integration responsibility.
Mechanical Mounting (flange/thread), available space, duct geometry (for duct heaters) Include drawings or photos for OEM retrofits.
Materials Sheath material preferences, corrosion risk, contamination constraints Media compatibility determines material selection.
Safety Overtemperature protection, interlocks, airflow proving (duct), earthing Define required standards and site rules.
OEM tip: Share your assembly drawings early. We can align mounting, terminal enclosures, and cable exits to your manufacturing schedule.

Technical FAQ (Informative)

Accordion format
When should I choose a duct heater instead of an immersion heater?
Choose a duct heater when your process requires controlled heating of air or gases, not direct liquid heating. Typical cases:
  • Heating process air in drying, curing, or conditioning steps
  • Preheating ventilation air where stable temperature is needed
  • Heating inert gas streams or enclosed process zones
  • Applications requiring airflow proving and staged power control
What is a circulation heater and why is it common in asphalt plants?
A circulation heater heats a liquid in a controlled closed-loop, typically using a flow path through a pressure vessel. This approach is widely used when:
  • Inline heating is needed during transfer (stable flow and temperature)
  • Thermal oil circuits require controlled heat input
  • Process safety demands defined flow, sensors, and interlocks
It also helps avoid hotspots by ensuring the heater is operating under defined flow conditions.
How do you manage watt density for viscous media like bitumen?
For viscous media, correct design focuses on heat flux stability and controlled surface temperatures. Caldor Heat engineering evaluates:
  • Target temperature and viscosity range
  • Heat transfer conditions (stagnant vs flowing)
  • Element geometry and effective heated surface area
  • Control method (staging, SSR, thyristor, PID)
The objective is to maintain product quality and extend heater life by avoiding localized overheating.
What control and safety functions are recommended for duct heaters?
Industrial duct heaters typically use:
  • Airflow proving (pressure switch / airflow sensor) to prevent dry-fire overheating
  • Overtemperature limit (manual reset safety thermostat)
  • Staged heating or modulating control (SSR/thyristor) for stable outlet temperature
  • Interlocks with fan status and emergency shutdown circuits
Documentation can include wiring diagrams and recommended sensor placements for OEM integration.
What information is required to quote an OEM heater assembly quickly?
To accelerate engineering and quoting, provide:
  • Target application and medium (bitumen / thermal oil / air)
  • Voltage, phase, maximum installed kW
  • Mounting interface (flange / thread / duct frame) and available space
  • Temperature requirements and control method
  • Environmental constraints (outdoor, vibration, ingress protection expectations)
If available, attach a drawing (PDF/DWG) and photos of the mounting area.

Manufacturing Tests, Reports & Traceability

Quality documentation

Caldor Heat applies systematic quality controls to ensure electrical safety, mechanical integrity, and conformity prior to shipment. The following tests are typical for electric heating elements and assemblies.

Test Method / Criteria Documentation Output
Power Test (Cold Resistance) Resistance measurement with tolerance typically -5% / +10% vs nominal value. Resistance record, serial/lot traceability (as applicable).
Insulation Resistance DC test, commonly 500 V; minimum cold value typically > 100 MΩ. IR test result in report (per product type / agreement).
Dielectric Strength Test voltage commonly (2U + 1000 V) × 1.2 applied for 1 second. Hipot pass/fail record (and values when requested).
Final Electrical Control 100% final check prior to packing/shipping. Release confirmation and traceable packing reference.
Reports: Test reports, certificates, and inspection records can be supplied based on order requirements (e.g., per serial number, per batch, or per shipment documentation package).

Technical Information Form (Copy/Paste for RFQ)

Structured request

Use the fields below as a technical checklist for your request for quotation (RFQ). You can copy into email or your internal ERP.

Project & Application

Industry Asphalt / Bitumen / Thermal Oil / Process Air

Medium: ____________________   Duty: Continuous / Intermittent

Start Temp (°C): ____   Target Temp (°C): ____   Ambient (°C): ____

Location: Indoor / Outdoor   Ingress expectation: ____________

Duct Heater Data

Duct type: Rectangular / Round

Dimensions: ________

Airflow: ________ (m³/h)

Inlet/Outlet Temp: ____ / ____ (°C)

Airflow proving: Yes / No

Circulation Heater Data

Flow rate: ________

Fluid: Thermal oil / fuel oil / other

Pressure: ________

Connections: ________

Inline sensors: RTD / TC / none

Electrical & Control

Voltage: ____   Phase: 1~ / 3~

Total Power (kW): ____

Control: On/Off / Staged / SSR / Thyristor / PID

Safety limit: Auto / Manual reset

Attachments recommended: duct/tank drawings, photos of installation zone, process schematic (P&ID), site standards and required documentation list.

Need an OEM-Engineered Heating System for Asphalt Applications?

Send your process data and drawings. Caldor Heat (Romania manufacturing) will propose a duct heater, circulation heater, immersion solution, or a combined turnkey system aligned to your operating conditions and documentation requirements.

Contact us