When managing electric heating for industrial systems, a common question arises: Is it time to replace or retrofit our electric heaters? The answer depends on a range of factors — from compliance requirements and heating performance to space constraints and energy efficiency goals.
Whether you're operating a facility in Houston, TX, Los Angeles, CA, or anywhere across North America, making the right decision for your industrial heating needs starts with understanding the variables that influence system performance and lifecycle.
Replacing Electric Heaters vs. Retrofitting: Key Questions to Ask
Watlow® specializes in advanced electric heaters and thermal systems for industries ranging from aerospace to food processing. Our engineering experts and our online Digital Product Assistant can help you navigate the decision between replacing electric heaters or upgrading existing ones.
1. Should You Replace or Retrofit Your Industrial Heating System?
This is a critical first question. A retrofit may be more affordable than a full replacement and can often boost efficiency. However, retrofitting isn’t always viable — especially if:
-
The existing system is too outdated
-
Your heating requirements have changed significantly
-
Compliance with modern regulations cannot be achieved with retrofitting
2. What Are Your Goals for System Performance?
Clarifying your priorities can help define whether replacing electric heaters or retrofitting is the right move. Are you aiming to:
-
Improve thermal efficiency?
-
Reduce energy costs?
-
Support decarbonization efforts?
Each of these goals may point to different solutions in industrial electric heating systems.
Choosing the Right Industrial Electric Heater
Once you've decided whether to replace or retrofit, it’s time to choose the correct type of electric heater for your application.
3. What Material Will the System Heat?
The material being heated — gas, liquid, or solid — influences your heater choice. For example:
-
Low-watt density heaters are ideal for heating viscous liquids or sensitive materials
-
High-watt density heaters may be required for high-throughput gas applications
-
Factors like watt density, element length, and heater shape play a role in tailoring the heater for your needs.
4. What Compliance Standards Must Be Met?
Every industry faces different regulatory hurdles. For example, electric heating systems for industrial applications in the medical or aerospace sectors may face more stringent safety codes than general manufacturing.
Whether you’re replacing electric heaters or retrofitting, ensure that your new or upgraded solution complies with:
-
OSHA requirements
-
Local energy codes (especially in states like California or New York)
-
Industry-specific standards (e.g., FDA, UL, ISO)
5. What Are the Operating Temperature Requirements?
The desired operating temperature is another critical parameter. Watlow offers heater options that support a wide range:
-
Low-temperature flexible heaters (e.g., for lab or medical environments)
-
High-temperature ceramic fiber heaters (up to 2,250°F) for demanding industrial applications
6. What Are the Ambient Conditions?
Ambient airflow, enclosure design, and nearby equipment affect heater performance. Improper placement in high-humidity or low-temperature zones can compromise system efficiency or even cause premature failure.
7. Do You Have Space Constraints?
From compact flange heaters for tight enclosures to large-scale duct heaters used in massive HVAC systems, there’s a wide range of heater formats. Accurate space assessment ensures compatibility and safe integration into existing industrial layouts.
Need Help with Electric Heating for an Industrial System?
Whether you're operating in Chicago, Atlanta, or across North America, Watlow is here to help you make the right decision about your electric heating system. Our expert team can guide you through heater selection, sizing, compliance, and retrofitting options.
Watlow Services Include:
-
Expert consultation on replacing electric heaters
-
Application support for industrial electric heating systems
-
Online tools to simplify selection
-
Nationwide network of sales reps and distributors
Ready to optimize your industrial heating system?
Connect with Watlow® today to get guidance on retrofitting or replacing your electric heaters and explore the best electric heating solutions for industrial systems.