Case Study
Five Industries Transformed by Flexible Coil and Cable Heating Technology
Coil and cable heating technology has been so transformational for manufacturing because it itself is so transformational. Flexible enough to take on any shape and thin enough to weave through gaps that are impossibly tight for alternatives, these heaters have become the standard for industries that require high levels of precision, efficiency, and adaptability.
Before modern coil and cable heating was widely available, industries had to make do with systems that were harder to integrate in tricky spaces, which limited design options and made uniform heat distribution difficult. Coil and cable heaters enabled manufacturers to apply controlled, localized heat to intricate parts, curved surfaces, and hard-to-reach areas as they never could before.
“People look to them for solving complex heating challenges,” said Ryan, a Tempco Design Engineer, who has worked for five years on the company’s coil heaters and temperature sensors. “The size and flexibility of these heaters allow you to route them, shape them, form them, and do whatever a customer needs.”
Today, Tempco’s coil and cable heaters are helping manufacturers achieve better process control and greater design flexibility. Below are five examples of industries that have been revolutionized by this technology.
Heating in processes like injection molding, extrusion, and sealing was once provided by sources such as cartridge heaters, hot plates or ovens. These methods worked but were less adaptable to irregular or tight spaces, could create hot or cold spots due to poor contact or uneven distribution, and were harder to retrofit or adjust for design changes. Coil and cable heaters improved on these by conforming to complex shapes, delivering more uniform, localized heat, and allowing for lighter, more compact tooling.
“A lot of nozzles on the injection moldings need to stay warm so the plastic running through it doesn’t gunk up,” he said. “They use coil heating to wrap around any parts of the injection molding machine that plastic is running through so it can stay warm.”
Tempco Mini-Coil Band Heater designed for precision heating in hot runner injection molding systems.
Industrial coil and cable heaters from Tempco used for precision heating in various applications.
Semiconductor Manufacturing and Silicon Wafer Processing
One of the clearest examples of an industry that has been transformed by flexible cable and coil heating is semiconductor fabrication, which requires precise temperatures in tools like wafer chucks, pedestals, and gas delivery systems. Prior to the advent of coil and cable heaters, manufacturers often relied on bulky metal-sheathed heaters or external hot plates. These older methods were comparatively rigid, slow to respond, and could not conform as well to the intricate shapes of semiconductor equipment.
Coil and cable heaters allowed engineers to wrap or embed uniform, controllable heat exactly where needed, even around curved or confined surfaces. This enabled better process control, higher yields, cleaner operations, and more compact equipment designs, supporting the miniaturization and precision the industry demands today.
Energy and Power Generation (Gas Analysis and Monitoring)
Coil and cable heaters are widely used in gas analysis and monitoring systems to prevent condensation and maintain consistent temperatures. In sampling lines, probes, and gas cells, these heaters keep gases above their dew point to ensure accurate readings and avoid moisture-related measurement errors.
Their flexibility allows them to wrap around pipes, tubes, and irregular components, delivering consistent heat across complex layouts. This is especially critical in emissions monitoring, environmental testing, and process control, where precise temperature control of the gas stream preserves sample integrity. Easy to install, the coil and cable heaters also enable retrofitting on existing equipment and perform reliably in harsh or outdoor conditions.
Tempco-Pak Cable Heater with flexible design and high thermal conductivity for industrial heating applications.
Tempco flexible heating solutions for versatile industrial temperature control applications.
Industrial Process and Pipeline Systems (Process Heating and Freeze Protection)
Coil and cable heaters are used in industrial process and pipeline systems to maintain temperatures, prevent freezing, and ensure smooth material flow. They can wrap around pipes, valves, tanks, or pumps to deliver uniform heat, even on irregular surfaces. This is essential for keeping liquids or gases above their freezing or viscosity point, avoiding blockages, and ensuring consistent process conditions.
By protecting pipelines and critical components, flexible cable and coil heaters improve reliability, safety, and productivity in demanding industrial environments.
Laboratory and Research Equipment
Laboratory and research equipment widely rely on coil and cable to provide precise, localized heating in controlled experiments and sensitive processes. They can wrap around tubes, flasks, reaction vessels, or small components to maintain stable temperatures, prevent condensation, or drive chemical reactions.
Common applications include heating gas or liquid lines, maintaining sample cells at set temperatures, or simulating environmental conditions. In analytical instruments, they keep components like detectors or chambers at optimal temperatures for accuracy and repeatability.
The Next Industry to Be Transformed? Yours.
There’s little that coil and cable heating technology can’t do and almost nothing Tempco can’t accomplish with it. Whatever you need, you can share your specifications with the Tempco team and they’ll make it happen.
Contact Tempco’s application engineers to discuss how coil and cable heaters can solve your specific challenges. You can also explore our comprehensive Coil & Cable Heaters catalog to discover solutions that are revolutionizing industries worldwide.
