Heaters & Heating System

WHY CONVENTIONAL HEATING WASTES ENERGY

Corrugation machines frequently run paper that is narrower than the full width of the machine.

With conventional heaters, however, the entire roll is heated regardless of the width of paper being converted.

This means that when a smaller-width paper is being run:

• The portion of the roll actually involved in production requires heat.
• The unused portion of the roll continues to receive heat.
• Energy is consumed even though no paper is being converted in that area.
• Excess heat can build up in the unused portion of the rolls.
• Over time, this unnecessary heating can contribute to higher electricity consumption, reduced machine efficiency and increased wear of machine components.

These losses are often invisible during day-to-day operations because the machine continues to run normally. However, when repeated over hundreds of operating hours, heating unused areas of the rolls can represent a significant and avoidable energy cost.

THE ZONE HEATING SOLUTION

Electro Heat's Zone Heating System divides the heating area of the corrugating rolls into three independently controlled zones.

The operator can therefore select:

• Panel-side zone
• Centre zone
• Motor-side zone

Individually or in combinations, depending on the width and position of the paper being converted.

The required zones are switched ON through the control panel, while the unnecessary zones remain OFF.

This means that energy consumption is directly aligned with the actual production requirement.

The system's specially designed tubular heaters incorporate carefully selected heating elements, electrical insulation and tubular sheaths to maximise heat output while minimising electricity consumption.

HEAT ONLY WHERE YOU CONVERT

The fundamental advantage of Zone Heating becomes particularly significant when a machine regularly converts different paper widths.

A full-width machine may be capable of processing a wide range of paper sizes, but the actual production requirement can vary considerably from job to job.

With conventional heating, the heating load remains largely unchanged even when a narrower sheet is being converted.

With Zone Heating, the heating requirement changes with the job.

WIDER PAPER → MORE ZONES ON
NARROWER PAPER → FEWER ZONES ON

This simple principle ensures that the heating system uses only the energy required for the actual production width.

As the paper width changes, the operator can select the appropriate combination of zones through the control panel.

The result is a heating system that adapts to the production requirement instead of continuously heating the entire roll.

SIGNIFICANT ENERGY SAVINGS

Because unnecessary portions of the corrugating rolls do not need to be heated, Zone Heating can substantially reduce electricity consumption.

The system has demonstrated electricity savings of up to 30%, depending on machine size, paper-width mix and operating pattern. When full-width paper is being converted, the system can still deliver approximately 15% lower electricity consumption compared with conventional heaters, according to the product documentation.

The actual savings depend on the proportion of smaller-width paper being converted and the operating hours of the machine.

The greater the variation between machine width and actual paper width, the greater the opportunity for energy savings.

MORE THAN ENERGY SAVINGS

Zone Heating is not merely an electricity-saving system.

When a smaller-width paper is converted on a larger machine, the unused portion of the flute and pressure rolls can become excessively hot. This can cause the roll to expand in the unused area, potentially affecting pressure at the edge of the 2-ply and contributing to blister or bubbling formation.

By heating only the required portion of the rolls, Zone Heating helps control this unnecessary temperature build-up. The result is more consistent operating conditions and improved 2-ply quality.

PROTECT YOUR CORRUGATION MACHINE

Unnecessary heating of unused areas can also contribute to excessive thermal stress and wear on machine components.

The resulting problems can include:

• Cutting of flutes on the flute rolls
• Imbalances during machine operation
• Increased stress on bushes and bearings
• Jamming and maintenance issues
• Increased wear of rotary components

By concentrating heat only where conversion takes place, Zone Heating helps reduce unnecessary heating and associated wear, contributing to longer machine component life and reduced maintenance requirements.

LOWER ELECTRICAL LOAD

Zone Heating reduces not only the electricity consumed during production but also the overall electrical load requirement of the heating system.

A lower electrical load can reduce the burden on:

• Generator sets
• Main electrical supply
• Wiring
• Fuses and MCBs
• Transformers

This can contribute to improved efficiency and longer life of the associated electrical infrastructure.

DESIGNED FOR DIFFERENT CORRUGATION MACHINES

Electro Heat offers Zone Heating Systems in different configurations to suit different types of corrugation machines.

ZHS – STANDARD

Designed for conventional corrugation machines with fingers.

ZHS – DOUBLE

Available in configurations for higher-capacity heating requirements and fingerless machines, including imported fingerless corrugation machines.

The double configuration incorporates a higher number of tubes, providing increased heating capacity and enabling effective heating of individual zones.

DIGITAL TEMPERATURE CONTROL

Zone Heating is complemented by a Digital Temperature Control Panel, which enables convenient switching between heating zones while maintaining the optimum working temperature of the rolls.

This combination of zonal heating + accurate temperature control allows the corrugator to manage both:

WHERE heat is required
and
HOW MUCH heat is required.

The result is a more intelligent and efficient approach to corrugation heating.

THE ELECTRO HEAT ADVANTAGE

Conventional heating treats the entire roll as one heating area.

Zone Heating treats it as a production surface — heating only the areas that are actually working.

That difference may appear simple, but it has a significant impact on the economics and performance of a corrugation machine.

LESS WASTE. MORE CONTROL. BETTER ECONOMICS.

With Zone Heating, you don't have to pay to heat what you don't use.

You heat only where you convert.

PURE ENERGY MANAGEMENT

The Zone Heating System represents a fundamentally different approach to electric heating for corrugation machines:

Use less energy.
Heat only where required.
Maintain better control.
Protect the machine.
Improve 2-ply quality.

With more than 2,000 installations over two decades, Electro Heat's Zone Heating System is a proven solution for corrugators looking to reduce energy consumption while improving the efficiency and reliability of their heating process.