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Cartridge Heaters

Cartridge Heating Elements

Commonly used in the process heating industry, a cartridge heater gives you more power per square metre than any other metal-sheathed heating element. Cynebar cartridge heaters are typically custom made to suit your application to ensure you get the best possible result.

Cartridge heating elements are typically inserted into accurately reamed holes to heat metal parts and/or small spaces. Their power and compact size give the cartridge heater a wide range of applications. Efficient energy conduction into the work pieces ensures optimum heat transfer and fast heat recovery and reliability in tough operating conditions.

Example Applications

  • Plastic Processing & Injection Mold Dies
  • Platens & Hot Plates
  • Packaging Machinery, Glue Pots, End & Seam Sealing
  • Medical, Scientific & Laboratory Equipment
  • Fluids Heating

High Quality Cartridge Heaters

Insuring CYNEBAR can provide you with the optimum productivity alongside profitability, it is essential that the correct cartridge heater can be selected to insure all specifications are met to the highest quality and to your satisfaction.

By doing so, CYNEBAR can guarantee the upmost expertise and quality. We ensure constant support and information throughout your project development, so every item is addressed appropriately and on time.

Cartridge Heater

What are you getting?

CYNEBAR promises the following:

  • Enhanced quality design, shaped to your specific requirements
  • Utmost ingenuity and intelligence
  • Controlled Manufacturing and testing that insures; quality, reliability and consistency
  • Prime quality, durable materials. Yield the best guaranteed performance

Cartridge Heater Construction – Built To Last

Cartridge Diagram

“If the raw material quality does not measure up, neither will your cartridge heater+.”

Resistance Wire:

The standard Nickel chromium wire is calculated to gauge, length and spacing, wound on a supporting core and precisely centred to guarantee uniform temperatures and long life.


Our standard Incoloy® 800 sheath provides high-temperature resistance to oxidation and corrosion, proving far superior to 304 stainless steel alloys used by other manufacturers.


We use only high purity magnesium oxide (MgO), compacted to a carefully predetermined and closely monitored density. This assures high dielectric strength and fast heat transformation.

Lead Wire:

High temperature, flexible and fray-resistant wire available.

Source: Firerod

Preventing Heater Damage and Premature Heater Failure

Heating Cartridge

It is fundamental that you protect your heater from failure and contamination. Below are the four most common factors that contribute to premature heater failure:

  1. Contamination
  2. Corrosion
  3. Over Temperature
  4. Lead wire failure


Contamination occurs when foreign materials enter a heater’s internal area resulting in a breakdown of the element or insulation materials. Contaminants are usually organic and cause either a gross electrical short to ground or an accelerated deterioration of the heater’s internal elements and/or power leads.


Corrosion occurs when the heater’s outer sheath deteriorates and allows contaminants to enter the heater.

Over Temperature:


The internal construction of your heater is designed and based on the wattage and operating temperature that you specify. However, various conditions can cause the heater to reach over temperature.

The incidence of heater over temperature is minimized by reducing mineral deposit build up, correctly sizing a hole to fit the heater and choosing the optimum heater insertion length and sensor location.

A heater that is forced to operate beyond its maximum operating temperature is destined for premature failure. Extreme over temperature conditions will cause the heater’s internal conductors to melt. Less severe over temperature conditions will accelerate a heater’s normal aging process. Operating a heater 37°C (100°F) beyond its maximum recommended temperature can reduce heater life by as much as two-thirds.

Lead Wire Failure:

The following steps are installed to insure lead failure does not occur.

  1. Matching lead wire with application temperature
  2. Provide Relief to Over-Flexed Lead Wire
  3. Put a Barrier Between Lead Wires and Heater Parts

All three steps can be averted with proper communication between the engineer and you.

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