For OEMs designing the next generation of heating, ventilation, and air conditioning systems, electric heaters—especially flanged heaters—are proving indispensable. But what makes precise electric heating so critical in HVAC? And how do different heater types fit into the complex puzzle of modern climate control?

A Smarter, Safer Heat: Why OEMs Are Powering Up with Electric Air Duct Heaters

Increasingly, OEMs are making the move from gas to electric air duct heaters—and for good reason. Electric units, especially those featuring efficient tubular finned elements, deliver powerful performance with zero direct emissions. They align with today’s sustainability goals, integrate easily with renewable energy systems, and eliminate the safety concerns tied to gas combustion. The result? Cleaner, safer, and more future-ready HVAC solutions that today’s market demands.

This resource page explores the importance of precision heating, and how you can depend on electric heater technologies to shape the future of efficient, sustainable buildings.

Backer Hotwatt air process heaters are high-performance electric heaters designed to deliver precise, controllable hot air and gas for a wide variety of industrial and commercial applications. Capable of providing air and gas temperatures up to 1000°F (540°C), these heaters offer infinite control by adjusting the voltage and air velocity, making them ideal for processes that demand both flexibility and accuracy.

These heaters are commonly used in applications such as baking, drying, laminating, metal working, packaging, plastic welding, preheating, sealing, soldering, shrink fitting, and synthetic fabric sewing. Their robust design accommodates multiple wattage circuits, allowing for quick heat-up, standby maintenance, and adaptation to varying thermal loads—all while maintaining tight wattage tolerances of +5%, -10% or better at the specified voltage.

Backer Hotwatt offers a range of air process heater types—including standard tee, maximum flow, pure flow (for clean air needs), and heavy-duty models—each engineered for specific flow rates, temperature ranges, and installation requirements. Custom options include various diameters, lengths, mounting fittings, and electrical connections to suit diverse operational needs.

Key Features:

Typical Applications:

Backer Hotwatt Air Process Heater Features & Options

Backer Hotwatt air process heaters combine durability, versatility, and precise control, making them a trusted solution for demanding air and gas heating tasks across a broad range of industries.

Unit Heaters

Unit heaters are single-source, self-contained electric or gas-based heating devices designed to warm larger areas such as warehouses, garages, workshops, or commercial spaces with high ceilings or open layouts. Unlike duct heaters, which are integrated into a building’s ventilation system to heat circulating air, unit heaters feature a dedicated heating element paired with a built-in fan or blower that distributes heated air directly into the space.

Typical unit heater installations involve ceiling or wall mounting for optimal airflow and coverage. With their powerful output and focused design, unit heaters are especially efficient for spot heating and for spaces where central heating may be impractical or insufficient. Multiple units can be arranged to work in tandem, ensuring uniform comfort in large or high-loss environments. Unit heaters offer rapid heat delivery and are ideal for applications needing supplemental or primary heat in zones that are difficult to reach with conventional ducted systems.

By combining unit heaters for targeted comfort, and duct heaters within the air handling system, HVAC engineers and building managers can achieve tailored heating solutions that maximize energy efficiency, responsiveness, and user comfort across residential, industrial, and commercial spaces.

Backer Hotwatt offers a range of unit heaters engineered for powerful, reliable space heating in large environments such as warehouses, workshops, garages, and commercial spaces. These heaters are specifically designed for spot heating and efficient comfort delivery where centralized systems are not practical.

Key Features:

Typical Applications:

• Space heating for warehouses, garages, workshops, commercial buildings

• Supplemental and primary heating in zones difficult to reach with central systems

• Rapid comfort delivery for spot heating in open layouts and areas with high ceilings

Backer Hotwatt Unit Heater Features & Options

Backer Hotwatt unit heaters combine engineering flexibility and reliable comfort to meet challenging heating needs for industrial and commercial environments.

Inline Fluid/Gas Heating

Key Features Include:

• Versatility:

Customizable in size, sheath, leads, terminals, wattage, and voltage for a wide variety
of applications.

• Precision Heating:

Provides localized, uniform heat for dies, platens, molds, and other processing equipment.

• High Performance:

Closely controlled work temperatures up to 1400°F (760°C); high watt density options for
fast response and high-temperature needs.

• Durability:

Swaged construction and robust materials (stainless steel, Incoloy, titanium) ensure long life, even
under tough conditions.

• Special Features:

Options for square/rectangular cross-sections, end seals, liquid-tight construction, and lead
protection for harsh environments.

• Certifications:

U.L. Recognized and C.S.A. Certified for safety and quality assurance.

Typical Applications:

Backer Hotwatt Cartridge Heater Features & Options

Backer Hotwatt cartridge heaters combine adaptability, precision, and rugged construction, making them a trusted solution for OEMs and engineers seeking efficient and reliable heating in even the most challenging environments.

Strip & Finned Strip Heaters

Key Features:

• Wide Application Range

Used for heating dies, molds, platens, cylinders, tanks, kettles, process machines, and

for air heating in ovens and load banks.

• Construction Options:

- Mica-insulated strip heaters:

Feature a rust-resistant steel sheath, mica insulation, and resistance ribbon wire for dependable performance and good dielectric strength.

- Ceramic-insulated strip heaters:

Built with a seamless stainless-steel sheath and ceramic supports, offering high dimensional stability and efficient heat transfer, particularly in milled slots.

- Finned strip heaters:

Incorporate aluminum or stainless-steel fins to maximize radiating surface, providing rapid heat transfer to air for ovens, ducts, and forced-air heating.

• Flexible Installation:

Can be used singly or in groups, and are best clamped securely to heated surfaces for maximum heat distribution and to prevent distortion.

• Customizable Terminations:

Multiple terminal and lead options (post terminals, high-temperature insulated leads, ring terminals, quick-connects) to suit diverse installation needs.

• Certifications:

U.L. Recognized (E56973) and C.S.A. Certified (016386-0-000) for safety and quality assurance.

• Made in the USA:

Manufactured to high standards for reliability and performance.

Typical Applications:

Backer Hotwatt Strip & Finned Strip Heater Features

Backer Hotwatt tubular and finned tubular heaters combine ruggedness, flexibility, and efficient performance, making them a trusted solution for demanding heating applications across a wide range of industries. We speak more about the benefits of tubular finned heaters in this blog.

Real-World Example

In a commercial hydronic heating system, flanged immersion heaters are installed in the main water storage tank. As the system circulates water through the building, the heaters maintain the desired temperature with high precision, ensuring consistent comfort while minimizing energy use. The robust design and direct immersion method mean the system can operate reliably for years with minimal maintenance.

Flanged heaters are essential components in modern HVAC systems, offering efficient, reliable, and customizable heating for liquids, gases, and air. Their robust construction, precise control, and adaptability make them a cornerstone technology for OEMs and facility managers aiming for high performance and long-term operational success.

How Flanged Heaters Handle Different Types of Fluids in HVAC Systems

Flanged heaters are highly adaptable heating solutions in HVAC systems, capable of efficiently transferring heat to a wide variety of fluids, thanks to their direct immersion design and secure flange mounting. They are engineered with different sheath materials—such as stainless steel or copper for water, Incoloy, or titanium for corrosive fluids such as brine and deionized water, and Hastelloy or specialty coatings for chemical and caustic solutions—to ensure optimal compatibility and durability.

For oil heating, flanged heaters use lower watt density and specialized materials to prevent overheating and prolong heater life, while glycol-compatible options are widely used for freeze protection in hydronic loops. Integrated temperature controls, including thermocouples and high-limit sensors, provide real-time feedback and safety.

This versatility allows flanged heaters to be customized for applications ranging from hot water storage and freeze protection to preheating oils and maintaining chemical solutions, making them a reliable and efficient choice for both standard and specialized HVAC needs.

Customization and Integration: The OEM Perspective

One of the standout advantages of electric heaters—especially those from Backer Hotwatt—is their customizability. OEMs can specify:

• Materials:

From standard steel to high-grade Incoloy for corrosive environments.

• Power Ratings:

Tailored to the exact heating load.

• Control Features:

Integrated sensors, thermostats, and safety cutoffs.

• Form Factors:

Compact designs for tight spaces or large-scale units for central plants.

This flexibility enables OEMs to design HVAC systems that are efficient and reliable, while also tailored to the unique needs of each project.

Sustainability and Cost Savings

Electric heaters play a pivotal role in reducing the carbon footprint of HVAC systems. By operating on renewable electricity and delivering heat exactly where and when it’s needed, they help building-owners achieve sustainability goals while minimizing energy waste.

Long-Term Value

Durable construction and minimal maintenance requirements mean that electric heaters offer a lower total cost of ownership compared to many traditional systems. Their scalability also allows OEMs to future-proof their designs as building needs evolve.

Real-World Impact

• Data Centers:

Electric duct heaters paired with smart controls maintain precise humidity and temperature, protecting sensitive servers and reducing downtime.

• Pharmaceutical Manufacturing:

Flanged and immersion heaters ensure that process water is kept within strict temperature tolerances, supporting product quality and regulatory compliance.

• Green Buildings:

All-electric HVAC systems featuring Backer Hotwatt flanged heaters help commercial developers achieve LEED certification and meet local emissions targets.

How Does Watt Density Affect the Performance of Flanged Heaters in HVAC Systems?

Watt density—the amount of power (watts) applied per unit surface area of a heater element—is a critical factor influencing the performance, efficiency, and longevity of flanged heaters in HVAC systems.

There are four variables for operational consideration regarding watt density:

1. Heating Rate and Temperature Control

Higher watt density means more heat is generated per square inch of the element, resulting in faster heating and quicker temperature rise.

2. Efficiency and Uniformity

An appropriately matched watt density ensures efficient heat transfer and uniform temperature distribution.

3. Heater Longevity and Maintenance

Lower watt density generally results in lower surface temperatures on the heating element, which reduces thermal stress and the likelihood of scale buildup or element burnout.

4. Application Suitability

Selecting the correct watt density depends on the specific HVAC application and the properties of the medium being heated.

Effects of Watt Density on Flanged Heater Performance

Choosing the optimal watt density for flanged heaters in HVAC systems is essential. Too high, and you risk overheating, inefficiency, and premature failure; too low, and heating may be insufficient or slow. Properly matched watt density ensures efficient, uniform heating, system reliability, and long service life.

What Should OEMs Consider Next?

As you design your next HVAC solution, consider:

• Integration with Controls:

Modern electric heaters can be seamlessly integrated with building automation and
IoT platforms for real-time monitoring and optimization.

• Safety and Compliance:

Look for heaters with UL, CSA, or other relevant certifications, and ensure they
include necessary safety features.

• Maintenance Planning:

While electric heaters are low-maintenance, periodic inspection and cleaning can
further extend their life.

Precise, Efficient HVAC Heaters for Controlled Environments

Backer Hotwatt’s engineering team is here to help you design the optimal electric heating solution—whether you need a custom flanged heater for a new hydronic system, or a robust duct heater for a retrofit.

When it comes to controlling the environment of your application, heat and temperature are crucial to consider. Selecting the right heating element helps ensure the level of efficiency, allows you to attain optimal performance, and improves the overall lifespan of the heater’s end use. We’re committed to supporting OEMs as the HVAC industry transitions to a cleaner, smarter future.

Whatever your design or engineering challenge is, Backer Hotwatt has the expertise and broad technology base to develop a customized and dependable product for your unique needs. Whether you are heating air, fluids, gases, or other surfaces, our engineers can develop a solution that helps your application function most efficiently.

Established in 1952, Backer Hotwatt, Inc. has been a trusted source of superior quality heating elements for OEMs in the HVAC/refrigeration, medical, industrial, semiconductor, commercial, packaging, instrumentation, aviation, transportation, and military fields for over 70 years. We’re here to help you design and manufacture the best heater for your demanding and precise needs.

How can we help you with your next heating project? Contact us today to set up a consultation and see how our electric heaters can power your next generation of efficient, sustainable HVAC systems.

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