Going Green with Efficiency, Customization, and Optimized Heat Transfer
The electrification of the HVAC (heating, ventilation, and air conditioning) industry is a growing trend as the world transitions toward cleaner, more sustainable energy sources. This shift involves replacing traditional fossil-fuel-based heating and cooling systems with more efficient, electric-powered technologies.
Large-scale systems for office buildings, factories, and warehouses are transitioning to electric solutions and energy-saving HVAC systems, powered by renewable electricity, are being implemented in urban areas worldwide.
The trend towards electrification is driven by the rising need for cost-effective and energy-efficient space cooling and heating applications in the commercial and industrial sectors. The HVAC market is growing rapidly. In 2024, the global HVAC systems market size was estimated at $249.37 billion and is projected to grow at a CAGR of 7.5% from 2025 to 2030. [i]
Flanged heaters play a critical role as the HVAC industry shifts to electric power, enabling the development of efficient and reliable heating solutions across various applications. These heaters are known for various attributes, including:
- Robustness
- Versatility
- Ability to deliver high levels of heat in a compact form
What Are Flanged Heaters?
Flanged heaters are industrial-grade heating devices that consist of tubular heating elements mounted onto a flanged. These are typically inserted into tanks, ducts, or pipes to heat liquids, gases, or air. Flanged heaters are used in commercial HVAC applications to maintain process temperatures in industrial HVAC systems.
Typical applications in the HVAC industry include:
- Liquid Immersion Heaters
- Ideal for heating water in boilers, storage tanks, and hydronic systems.
- Feature thermocouples or thermostats for temperature monitoring.
- Circulation Heaters
- Used to heat liquids or gases in closed-loop systems.
- Integrated pumps circulate fluids for even heating.
- Duct Heaters
- Designed to heat air flowing through HVAC ducts.
- Often paired with blowers or fans for effective air distribution.
Benefits of Flanged Heaters in HVAC Systems
Flanged heaters provide a wide range of benefits when used in conjunction with the electrification of HVAC systems. Backer Hotwatt’s tubular flanged heaters are energy efficient, providing precise temperature control and direct heating of air, water, or fluids to minimize energy loss. Our heaters are fully customizable and can be engineered for various power ratings, temperatures, and materials, as well as specific HVAC applications like high-pressure or high-temperature systems.
Often, HVAC applications require a compact heater design to fit in small spaces. Backer Hotwatt’s flanged heaters are easily customized to fit precise HVAC system and power rating requirements. We offer a wide range of materials—steel, stainless steel, copper, and Incoloy—that hold up in demanding environments, such as exposure to harsh chemicals or high humidity, and are highly resistant to corrosion and thermal stress.
In addition, Backer Hotwatt flanged heaters are cost effective, scalable, long-lasting, and environmentally friendly. Our made-in-the-U.S.A. heaters are designed with durable materials for long life and minimal maintenance and are easily scaled for different applications. By enabling reduced energy consumption, flanged heaters help to reduce operating costs over time and lessen the environmental impact of HVAC operations.
The OEM Switch to Electric Air Duct Heaters
OEMs are rapidly switching from gas to electric air duct heaters to meet growing demands for sustainability, safety, and efficiency in HVAC systems. Electric units, especially those using tubular finned heaters, support decarbonization goals by producing zero direct emissions and integrating easily with renewable energy sources. They also eliminate risks associated with gas leaks and combustion, making them safer for all environments.
Tubular finned heaters are leading this transition thanks to their superior heat transfer—spiral-wound fins increase surface area, delivering faster, more uniform heating while reducing energy waste and extending heater life. Built from corrosion-resistant materials, they withstand harsh conditions and can be customized for tight spaces or specific HVAC needs. Their robust design minimizes electrical hazards and prevents ignition of airborne particles, enhancing reliability and safety.
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Benefits of Tubular Finned Heaters in Air Duct Heaters |
Description |
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Superior Heat Transfer |
Increased surface area enables faster, more uniform heating and higher efficiency. |
|
Energy Efficiency |
Maximizes heat output while minimizing energy waste, lowering operating costs. |
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Durability |
Constructed from corrosion-resistant materials (e.g., stainless steel, Incoloy) for long life in harsh environments. |
|
Customizability |
Can be tailored in shape, size, and power rating to fit specific duct or system requirements. |
|
Compact Design |
Delivers high heat output in a compact form factor, ideal for space-constrained installations. |
|
Enhanced Safety |
Enclosed design reduces risk of electrical shock and ignition of airborne particles, unlike open-coil heaters. |
|
Reliability |
Consistent performance and lower risk of failure due to robust construction and lower operating temperatures. |
|
Easy Integration |
Suitable for both new systems and retrofits, and pairs well with flanged heater assemblies. |
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Renewable Energy Compatibility |
Works efficiently with variable power sources like solar or wind, supporting decarbonization efforts. |
|
Lower Maintenance |
Extended heater life and fewer service requirements reduce long-term maintenance costs. |
By incorporating tubular finned heaters into flanged heater assemblies, OEMs benefit from scalable solutions that fit both large industrial and compact residential systems. These heaters lower lifetime costs through reduced maintenance and energy consumption, and they help OEMs future-proof their HVAC offerings for a sustainable, electrified future.
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. We look forward to helping you soon.
[i] https://www.grandviewresearch.com/industry-analysis/hvac-equipment-industry