Electric Heaters in HVAC

A Quick-Look Resource for OEMs

The electrification of the HVAC industry is accelerating as commercial and industrial sectors seek cleaner, more efficient solutions. Electric heaters—especially flanged heaters—are at the forefront of this transition, delivering precise, reliable, and customizable heating for a wide range of HVAC functions.

The Importance of Precise Heating in HVAC Functions

When it comes to HVAC performance, precision heating isn’t just a nice-to-have—it’s essential. From maintaining indoor comfort to supporting complex commercial and industrial processes, tight temperature control directly impacts efficiency, reliability, and air quality. Precise heating ensures that systems run smoothly, conserve energy, and protect both equipment and the people who depend on them. Whether you’re managing humidity, controlling process stability, or working to extend system life, consistent and accurate heating is the foundation of HVAC success.

Why Precision Matters

• Temperature Control: Maintaining precise temperatures is critical for comfort, energy efficiency, and system reliability. Accurate temperature regulation ensures that HVAC systems only run as long as necessary, reducing energy consumption and operational costs.
• Humidity Management: Many HVAC applications require strict humidity control, which is directly tied to accurate heating. Inconsistent temperatures can cause humidity swings, impacting indoor air quality and occupant comfort.
• Process Stability: In industrial and commercial settings, precise heating is essential for processes such as hydronic heating, air handling, and hot water supply. Even minor deviations can disrupt operations or damage sensitive equipment.
• System Longevity: Properly controlled heating reduces wear on system components, minimizing maintenance and extending equipment life.

 Key HVAC Functions Requiring Precise Heating

• Space Heating: Ensures occupant comfort and energy efficiency in commercial buildings, offices, and warehouses.
• Process Heating: Maintains specific temperatures for industrial processes, such as chemical manufacturing or food processing.
• Hot Water Generation: Provides consistent hot water for hydronic heating, sanitation, or process needs.
• Humidity Control: Supports dehumidification and air quality management in climate-controlled environment

Types of Electric Heaters Used in HVAC and Their Functions

In modern HVAC systems—especially those shifting toward electrification—precision heating starts with the right components. Flanged heaters are often the unsung heroes, providing the backbone of reliable, efficient heat across a wide range of applications. Whether it’s maintaining process temperatures in boilers, supporting hydronic systems for building comfort, or delivering critical heat in industrial processes, flanged heaters and their counterparts are engineered to perform. Let’s take a closer look at the key types of electric heaters driving performance, efficiency, and flexibility in today’s HVAC systems.

Flanged Heaters: The Backbone of Electrified HVAC

• What They Are: Industrial-grade heaters with tubular elements mounted to a flanged, inserted into tanks, ducts, or pipes to heat liquids, gases, or air.
• Key Applications:
  • Boilers & Hot Water Tanks: Maintain process temperatures for heating and sanitation.
  • Hydronic Systems: Provide reliable, even heating for building-wide comfort.
  • Process Heating: Used in industrial HVAC to heat process fluids or maintain critical temperatures.
• Advantages:
  • Robust and corrosion-resistant (available in steel, stainless steel, copper, Incoloy^®)
  • Customizable for power, temperature, and size requirements
  • Precise temperature control with integrated thermocouples or thermostats
  • Compact design for easy integration in tight spaces
  • Energy efficient, reducing operating costs and environmental impact

Duct Heaters

• Function: Heat air as it passes through HVAC ducts, often paired with blowers or fans for effective distribution.
• Use Cases: Space heating in large commercial buildings, supplemental heating in ventilation systems.
• Benefits: Rapid response, direct heating, minimal energy loss, easy to retrofit.

Circulation Heaters

• Function: Heat liquids or gases in closed-loop systems, ensuring even temperature distribution.
• Use Cases: Hydronic heating loops, process heating for industrial fluids.
• Benefits: Integrated pumps, compact footprint, precise control.

Other Electric Heater Types

• Strip & Tubular Heaters: Used for surface or direct heating in panels, enclosures, or radiators. Offer flexibility in design and mounting.
• Radiant Heaters: Provide targeted, efficient heating for specific zones or surfaces.

Real-World Use Cases

• Commercial Office Buildings: Flanged heaters maintain consistent hot water supply for hydronic heating, optimizing comfort and reducing energy costs.
• Industrial Warehouses: Duct heaters provide rapid, efficient space heating, minimizing downtime and ensuring worker comfort during winter months.
• Manufacturing Plants: Circulation heaters keep process fluids at precise temperatures, critical for quality control in chemical or food production.
• Data Centers: Electric heaters integrated with smart controls maintain precise humidity and temperature, protecting sensitive equipment.

The Lure of Electric Heaters in HVAC for OEMs

Electric heaters are quickly becoming the go-to choice for OEMs designing the next generation of HVAC systems—and for good reason. They offer clean, efficient, and highly controllable heat, making them a smart fit for modern sustainability goals and precision-driven applications. With the ability to seamlessly integrate with advanced controls, support renewable energy initiatives, and be tailored to exact specifications, electric heaters are reshaping how OEMs think about performance and flexibility in HVAC design. Here’s why the switch to electric is gaining serious traction.

• Energy Efficiency: Electric heaters convert nearly all input energy into usable heat, with minimal loss and no on-site emissions.
• Smart Integration: Modern electric heaters can be paired with advanced controls and sensors for real-time monitoring and automated adjustments.
• Sustainability: Support decarbonization goals by operating on renewable electricity and reducing reliance on fossil fuels.
• Customization: OEMs can specify heater materials, sizes, wattages, and control options to match unique system requirements.

Featured Products from Hotwatt

• Tubular Flanged Heaters: Customizable for power, temperature, and material; ideal for boilers, tanks, and hydronic systems.
• Duct Heaters: Designed for efficient air heating in commercial and industrial HVAC applications.
• Strip and Finned Heaters: For surface and air heating needs.
• Cartridge and Immersion Heaters: For targeted, high-precision heating in specialized applications.

Additional Considerations for OEMs

• System Integration: Ensure electric heaters are matched to system voltage, power requirements, and control architecture.
• Safety and Compliance: Select heaters with appropriate certifications and safety features (e.g., high-limit sensors, corrosion-resistant materials).
• Sustainability Goals: Consider heaters designed for minimal energy loss and compatibility with renewable energy sources.

Electrified HVAC Power for the Future

Flanged heaters are readily integrated into HVAC systems powered by renewable energy sources. As the HVAC industry transitions to electric power, flanged heaters complement the shift to de-carbonized HVAC systems. Flanged heaters support energy-efficient designs, enhance system performance, and provide a durable, long-lasting heat supply.

Backer Hotwatt can help you design a flanged heating system that performs efficiently, optimizes heat transfer, and helps achieve sustainability goals. As an industry leader in the design and manufacture of custom flanged heaters, we understand the nuances and complexities involved in bringing new technologies to market. By collaborating early in the design process, we will help you develop an optimal electric heating solution for your HVAC application.

How can we help you with your next HVAC heating project? Contact an engineer today to set up an exploration consultation. Let’s discuss your next HVAC heating project and discover how customizable electric heaters can optimize your system’s performance and sustainability.