Tubular Heating Elements & Immersion Heaters UK | Custom Manufactured
Soloheat first manufactured tubular sheath wire elements in 1980, and have since built a stock of thousands of elements in different sizes, power and voltages.
We can supply straight or formed tubular elements to customer requirements, in a range of configurations to suit single and multi-phase connections.
Terminations are built to customer specifications and can include threaded fittings / boss, thermocouple & thermostat pockets, terminal enclosures, hard-wired and more (see below). We also offer single ended elements should clients require a completely sealed heating element.
We have a large range of CAD drawings / 3D models on file, but if bespoke elements are required we can use clients samples as a template to reverse engineer an exact copy.
We can also supply 7.5mm, 5.5mm & 3.3mm flat section elements for use on higher temperature applications where improved Surface Heat Transfer is required, which can also be made with integrated thermocouples.
What Are Tubular Heaters?
Tubular heaters are among the most versatile and durable industrial heating elements available. Manufactured from a metal sheath containing a high-quality Nickel Chrome resistance wire insulated with compacted magnesium oxide, they provide efficient, reliable heat transfer across a wide range of industrial and commercial applications. Their flexible design allows them to be formed into virtually any shape, making them ideal for air heating, liquid heating, contact heating, and custom OEM equipment.
At Soloheat, we manufacture custom tubular heaters to your exact specification, including a wide range of diameters, sheath materials, wattages, voltages, bends, mounting arrangements and electrical terminations.
How Tubular Heating Elements Work
When electrical current passes through the internal nickel-chromium resistance wire, heat is generated and efficiently transferred through the densely compacted magnesium oxide insulation to the outer metal sheath.
This construction provides excellent thermal conductivity while maintaining high electrical insulation and mechanical strength. The result is a robust heating element capable of operating at high temperatures with excellent efficiency and long service life.
Depending on the application, tubular heaters can be supplied straight or formed into complex three-dimensional shapes to maximise heat transfer and fit within confined spaces.
Applications
Tubular heating elements are used throughout industry wherever dependable process heating is required. They are equally suitable for heating air, water, oils and many other liquids when correctly specified.
Typical applications include:
- Ovens
- Duct heaters
- Mould heating
- Commercial catering equipment
- Water tanks & vessels
- Freeze protection
- Washing & drying equipment
- Chemical tanks
- Oil heating
- Plastics machinery
- Packaging machinery
- Food processing
- Pharmaceutical
- Laboratory
- HVAC
- Dry air heating
Technical Specifications Table
Every tubular heating element is designed specifically for its application. The specifications below illustrate our standard manufacturing capabilities. Alternative diameters, materials, voltages and configurations are available upon request to meet individual customer requirements.
Available Terminations
We can terminate elements to suit any application. Common types include:
- Threaded studs
- Flying leads (hard-wired or detachable)
- Terminal blocks
- IP enclosures
- Immersion boss
- Flange
- Silicone leads
- Armoured cable – steel braided or flexible conduit
Available Heater Forms
We can form straight lengths to fit any application. Common forms include:
- Straight
- U-shaped
- Hairpin (tighter formed than a standard U shape)
- Spiral
- Circular
- Rectangular
- Serpentine
- Square
- Multi-plane bends
Tubular Heating Element Watt Density Guide
Choosing the correct watt density is essential for achieving maximum heater life, fast heat-up times and reliable performance. Watt density refers to the amount of power generated per unit area of the heater sheath.
Every application is different. Using too high a watt density for the application can shorten element life, while too low a watt density may result in slow heating.
Our engineers calculate the optimum watt density based on your process, operating temperature and installation environment, ensuring your tubular heating elements deliver maximum performance and service life.
Need help selecting the correct heater? Contact Soloheat’s technical team for expert advice and a free quotation.
Frequently Asked Questions - Tubular & Square Section Elements
What is a tubular heater?
A tubular heater is a versatile electric heating element consisting of a nickel-chromium resistance wire insulated by densely compacted magnesium oxide inside a metal sheath. This construction provides excellent heat transfer, electrical insulation and long service life. Tubular heating elements can be manufactured straight or bent into almost any shape for heating air, liquids or solid metal components.
What sheath material should I use?
The best sheath material depends on your application and operating environment. Stainless steel is suitable for many industrial processes and offers excellent corrosion resistance. Incoloy® is often selected for higher operating temperatures and more demanding environments, while copper is commonly used for water heating applications. Our engineers can recommend the most suitable material for your application.
What is the maximum operating temperature?
Maximum operating temperature depends on the sheath material, watt density and application. Tubular heating elements can typically operate at sheath temperatures exceeding 750°C, although the optimum temperature should always be selected to maximise heater life and reliability.
Can you copy an existing heater?
Yes. Soloheat regularly manufactures replacement tubular heating elements from customer samples or drawings. We can match the dimensions, bends, electrical ratings, fixing arrangements and terminal styles, while recommending design improvements where appropriate.
What diameter should I choose?
Common tubular heater diameters include 6.5mm, 8.0mm, 8.5mm, 10.0mm, 12.7mm and 16mm. Smaller diameters are ideal where installation space is limited, while larger diameters generally provide increased mechanical strength and higher power capability.
Can tubular heaters be bent?
Yes. One of the main advantages of tubular heating elements is their flexibility. They can be formed into simple U-shapes, coils, spirals and complex three-dimensional designs to suit tanks, ovens, ducts, machinery and OEM equipment. All bends are carefully controlled to maintain heater performance and reliability.
Do you manufacture immersion heaters?
Yes. Soloheat manufactures custom immersion heaters using tubular heating elements fitted with threaded bosses or flanges. These are designed for heating water, oils, chemicals and process liquids across a wide range of industrial applications.
Can thermocouples be built in?
Yes. Integral thermocouples can be incorporated into tubular heating elements where accurate temperature monitoring or closed-loop process control is required. This provides faster temperature response and improved control compared with external sensors.
What watt density should I specify?
The correct watt density depends on the material being heated, operating temperature, heat transfer conditions and required heat-up time. Lower watt densities maximise heater life, while higher watt densities provide faster heating where adequate heat dissipation is available. Soloheat will calculate the optimum watt density for your application.
What information do you need for a quotation?
To provide an accurate quotation we typically require:
- Overall heater dimensions or drawing
- Diameter and formed shape
- Voltage and wattage
- Sheath material
- Operating temperature
- Heating medium (air, water, oil or metal)
- Mounting details
- Terminal style and lead configuration
- Quantity required
- Any photographs or samples available
If you’re unsure of any of these details, simply contact our technical team. We’ll be happy to help identify the correct tubular heating element for your application.
Why Choose Soloheat?
Soloheat combines decades of heating element manufacturing experience with responsive UK-based production to deliver high-quality tubular heaters with competitive lead times. Every heater is manufactured to meet your exact application requirements, ensuring optimum performance, reliability and service life.
Whether you require a one-off prototype, replacement heating element or volume production for OEM equipment, our experienced engineering team can advise on the most suitable design, watt density, sheath material and termination arrangement. We pride ourselves on providing fast quotations, technical expertise and flexible manufacturing, helping customers minimise downtime and achieve the best heating solution for their application.
- Manufactured in England
- Since 1980
- Same-day quotation
- Bespoke manufacture
- Reverse engineer existing heaters
- CAD design
- Fast lead times
- OEM supplier
- Export worldwide
To order or enquire
Click here to download our Tubular Heater survey sheet template
Alternatively, email us and provide as much of the following info as possible:
Please refer to our Term and Conditions regarding warranty. (Section 6)
More Electric Heating Element solutions – Links
Not sure this is the heater type for your application? Take a look at our other heating solutions:
- Cast Aluminium / Alum Bronze Heaters
- Ceramic Band Heaters
- Mica Band Heaters
- Nozzle Heaters – includes on-line store
- Cartridge Heaters – includes on-line store
- Thermocouples, Plugs & Cables – includes on-line store
For more information on Electric Engineering Principles, check out our Engineering Guide