Don’t let the initial setup of electric process heaters deter your move to electrification. With cutting-edge advancements from Watlow, transitioning from traditional gas-fired systems to electric heating solutions is not only feasible—it’s beneficial. Explore the components and benefits of electric process heating and discover how your facility can achieve decarbonization goals while improving performance with electric air heaters, circulation heaters, and band heaters.
The Importance of Electrification and Decarbonization
Industries across the globe are focusing on two core initiatives: decarbonization and electrification. With climate change driving regulatory and societal pressure, companies must evolve their thermal processes to remain competitive and responsible.
Why Decarbonize?
According to the We Mean Business Coalition, more than 700 global companies have committed to lowering carbon emissions. Electrifying heating processes—particularly with Watlow's advanced electric heaters—is a critical step. Key motivations include:
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Reducing internal operational costs and improving system efficiency
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Meeting national and international emissions regulations
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Building trust with customers through sustainable practices
Climate Change and Process Heating
Transitioning to clean, electric process heating minimizes fossil fuel reliance. Whether your business is in manufacturing, energy processing, or food production, shifting to air heating and electric heaters addresses environmental concerns while enhancing your brand’s reputation.
Understanding the Electrification Process
Electrification involves replacing carbon-based heating methods with electric alternatives. It supports net-zero emissions targets and aligns with clean energy sources like wind and solar.
Watlow specializes in complete electric heating systems—from band heaters and air heaters to circulation heaters and electric heat exchangers. Each solution is designed for performance, safety, and sustainability.
Heat Exchangers: The Foundation of Efficient Electrification
Electric heat exchangers and circulation heaters from Watlow allow for easy integration into existing systems. For industries requiring precision, Watlow's advanced temperature and power controllers provide unmatched process control.
While flexible and strip heaters may need more tailored configurations, band heaters and air heating systems offer scalable and effective options. Watlow's thermal solutions support engineers and OEMs through every step of the electrification journey.
Benefits of Switching to Electric Heating Products
1. Improved Energy Efficiency
Electric process heating systems are 10–30% more efficient than gas-based alternatives. They reduce energy waste through superior heat transfer—especially when paired with modern air heaters and optimized control systems.
2. Lower Total Cost of Ownership
Compared to traditional steam or hot water systems, Watlow's electric heaters offer:
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Reduced fuel costs
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Minimal maintenance
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Longer life cycles
This combination significantly lowers your total cost of ownership over time.
3. Enhanced Process Control
Products like the OPTIMAX® heat exchanger deliver superior fluid dynamics and advanced pressure drop technology. Integration with F4T® PID controllers and ASPYRE® power controllers offers precise temperature regulation and diagnostics.
4. Increased Safety
Electric systems remove the need for in-tank maintenance common with boiler systems. Remote monitoring further protects your personnel by distancing them from heated zones during operation.
Integration and Control: Complete Electric Heating Solutions
Watlow® offers a seamless system approach to electrification and decarbonization solutions. From band heaters to air heaters and circulation heaters, your facility can transition to a cleaner system without losing performance.
Advanced power controllers and thermal loop integration allow for:
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Embedded diagnostics
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Smart communication protocols
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Customizable firing modes
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Full automation capabilities
Local Utility Incentives for Electrification
Take advantage of local utility incentives for installing electric heaters. Many utility providers offer rebates for switching from gas to electric process heating, especially for systems using circulation heaters and air heating components.
Go Green with Watlow®: A Global Leader in Electric Heating Systems
Watlow® is leading the charge toward a greener future with customizable thermal solutions for a wide range of industries. Whether you're electrifying food processing, vaporizing systems, or diesel exhaust treatment, our team provides the technical expertise and product innovation to make it happen.
Our Flagship Products Include:
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OPTIMAX® and HELIMAX® heat exchangers – High-efficiency circulation heaters
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Flexible heaters, strip heaters, band heaters, air heaters, and more
Start Your Electrification Journey Today
Electrifying your process heating system is a powerful step toward decarbonization. With Watlow's end-to-end support and thermal engineering expertise, your company can meet sustainability goals while improving operational efficiency.
Contact Watlow® today to learn more about electrification and decarbonization solutions and discover how electric heaters and circulation heaters can future-proof your operations.