Case Studies

Custom Solutions. Customer successes.
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testing laboratory process heating and controls 5
The DNA sequencing process involves multiple PCR cycles which involves specific temperature shifts for specific dwell times.
chemical processing
TPCI generator helps to regulate and stabilize heat transfer fluid temperature.
power turbine blades

The customer uses piping and metal parts in the fabrication of high speed turbines and compressors. In addition, the customer also rebuilds used turbines and compressors. 

aerospace weapon systems
Components for interceptor and ICBM rockets must be tested for reliability prior to deployment. 
laboratory glassware
Sanitizing duty in the ware washers requires compliance with NSF/ANSI 3 standards.
aircraft industry process heating and controls
A Virginia aircraft testing facility utilizes compressed air to test aircraft devices, throttling it from the source starting at 3,800 psi down to 1,650 psi down to 5 psi. 
testing process heating and controls
Chromalox was asked by a leading designer and manufacturer of custom solenoids and solenoid valves to collaborate on a new micro-solenoid valve heating project.
aircraft industry aircraft engine
Pressure relief valves used in the fuel lines of jet turbine engines need to stand up to rigorous testing. 
medical devices
Medical equipment manufacturer uses Chromalox cartridge heater for balloon catheter manufacturing process to meet strict size and electrical safety certification requirements.

Chromalox developed a safe, reliable cartridge heater using deep draw technology to prevent in-flight short circuiting of coffeemakers for airlines.

petroleum industry heating and controls

An oil and gas production and exploration company’s test chamber, used to evaluate down-hole drilling components, needed heaters that could withstand pressures up to 35,000 pounds per square inch and temperatures up to 500° F.

medical research process heating and controls
Chromalox helps OEM client develop a specialized melting point apparatus for the melting of elements for research experiments in university laboratories.
chemical processing lubricants process heating and controls
Chromalox created a customized pipe rack module to fit the requirements of the extended area. Chromalox then delivered the pipe rack to the expansion site and incorporated it into the existing pipe rack module without fail.
natural gas industry process heating and controls
A manufacturer who designs, builds and markets natural gas, drying, filtering and conditioning skids required assistance in Factory Acceptance Testing on entire integrated skid in addition to the Acceptance Testing of each component.
DNA strand medical heating and controls
Replication and processing of DNA requires precise, uniform heating imitating the internal temperature system of the human body.
gas turbine operationg temperature controls
A 92 MW co-generation power plant fueled by natural gas utilized two 46 MW gas turbines that required fuel gas treatment and preheating for increased efficiency.
DRA equipment

A major medical laboratory came to Chromalox when an issue with a lab instrument occurred.

trucking industry comfort heating
A manufacturer of large tanks for DEF required protection from both freezing and maximum degree temperatures. 
industrial process heating and controls 4
Glass-Lined and Hastelloy® Jackets used in hazardous chemical manufacturing are extremely sensitive to changes in temperature and can easily crack and be destroyed.
faux rock wall
For consistent production of imitation landscaping stones, their molds must be heated uniformly.
aerospace industry process heating and controls
After the Columbia shuttle tragedy, Chromalox played a crucial role in making the shuttle safer.
transportation industry comfort heating 3

This transportation equipment OEM's engineering team was challenged with providing comfort heat in the seating area of passenger cars.

outdoor storage tank heating and controls
Chromalox control panels are easily configured to accept a signal of current level status from a level controller installed within tanks.
industry smokestacks
Chromalox helps OEM manufacturer create mechanism for maintaining exhaust sampling and analyzing equipment to ensure safe pollution control from factory stacks.
construction vehicle
Chromalox engineered and manufactured innovative heaters for Diesel Exhaust Fluid (DEF) to meet the EPA standards of emissions from mobile heavy machinery.
nuclear power plant process heating
To test simulated fuel components, it was necessary to pre-heat carbon dioxide gas, CO2, used as a coolant in a high temperature gas-cooled nuclear reactor.
industrial testing chambers heating and controls
A premier global supplier of environmental test chambers to the scientific, industrial, and defense markets, must design equipment with the capability to perform testing in accordance with a wide variety of test standards.
waste oil heating and controls
A waste oil heater manufacturer was using an existing immersion heater to heat water that would then preheat the oil in the company’s oil heating system used for manufacturing. 
nuclear power plant
Inlet temperature of demineralized feed-water must be controlled to properly test heating element. Required temperatures range from not less than room temperature up to 600° F.
aerospace industry heating process
A manufacturer of cryogenic systems for use in the aerospace industry had a critical need for a methane conversion system. 
engine preheating
Chromalox helped this transportation industry customer solve an unusual heating system design challenge. A heated water/glycol mixture is used to preheat the engines of the customer's locomotives.
virus image
Scientists use liquid nitrogen to freeze and preserve samples for analysis through 3D, X-ray imaging. The resulting nitrogen gas interfered with the delicate operation of the specialized microscope lens.
silicon wafer production process heating and controls

An intricate part in the manufacture of electronic components and solar panels, the polysilicon process, requires high temperatures, high pressure and a low flow rate to succeed.

commercial building heating and temperature controls
The cooling towers of a Virginia medical facility's HVAC system required an upgrade to ensure freeze protection. 
fiberglass production heating and controls
An Arkansas manufacturer of fiberglass tanks needed to heat the a specific tank at a constant 100° F, but was concerned about potential tank wall breach due to high watt density.
industrial painting heating
An international manufacturer of epoxy industrial coatings spray systems sought help in reducing the footprint and expense of the control system that maintaining minimal system temperatures. 
chemical plant heating controls
Heat trace control panels cost-effectively monitor and control potential fault conditions on outdoor piping and storage tanks.
aerospace industry jet turbine
In an aerospace testing lab, air was to be heated to simulate temperatures from jet engines for the purpose of testing aircraft turbine units.
power generation heating and process controls
A large custom motor and generator manufacturer required a Class 1 Division 2-rated condensation heater for its manufacturing line. 
sand mold
A core box oven used in a foundry required tight temperature control.  The core box is used for curing the resin binder in the sand.
hot water thermostat temperature controls
An old-fashioned flame-type 80-gallon water heater could not maintain 750 degree F water temperature to allow quick dissolution of lime in the softening process. 
metal forging heating

Metal parts must be thoroughly cleaned so that paint adheres for a good, lasting finish. This process uses a triclorethylene vapor degreasing method.

oil industry temperature controls

To reduce risk, it was important to preheat fuel oil used for stand-by power in case there was an interruption of natural gas supply.

metal foundary process heating

In this process, castings with the physical properties of forgings are possible through the use of deeply anodized aluminum molds.

textile industry process heating
An old steam preboarding machine used for shaping hosiery needed to be replaced.
bottle assembly line process heating and controls
In a continuous straight-line bottling facility, bottles are loaded into the line along which a pneumatic cleaning machine automatically removes all foreign matter. 
heat trace power transmission heating and controls
Chromalox model SRL self-regulating heating cable was the key to freeze protection of natural gas compressor stations and booster station requiring heat tracing of condensate lines, skid lines, de-hi piping, and control and meter tubing.
electronics industry process heating
In this testing process, cathode ray tubes must be heated before evacuating all the air from the tubes with a vacuum pump.
cryogenic industry temperature controls
Cryogenics means "the production of icy cold"; a synonym for the low-temperature state. The customer had an application in which the piping (at cryogenic temperatures) formed ice.
hydroelectric power generation heating and controls

If dam gates freeze or suffer from ice or snow build-up, it interferes with the operation of the dam to open and close the flood gates as necessary to control the water levels.

heat trace industrial process heating and controls
A leading electric utility company has installed coal scrubbers and associated equipment, as well as a selective catalytic reduction (SCR) system.
industrial painting heating

An infrared lamp paint baking oven was a bottleneck, slowing all production, because it was unable to produce sufficiently high temperatures.

synthetic fiber production heating and controls
A North Carolina manufacturer of specialty synthetic fibers used in both home and industrial applications required a custom autoclave for a drying application. 
wastewater processing heaters and controls

Filtration membranes in two waste water treatment tanks at an Iowa ethanol producer were susceptible to damage from freezing temperatures. 

pasteurization process heating and controls
Several U.S. processors of nut meats required a processing system to pasteurize these nut products to meet validation requirements for proper log-kill doses of salmonella and other bacteria.  
chiller fan
A rating/testing agency that provides third-party approvals informed an HVAC manufacturer that one of its air-cooled chiller model’s fan circuit drives were not rated for the model’s maximum low temperature, negating the required approval.
asphalt production process heating and controls

A Wyoming manufacturer of road repair “crack-filling” mixtures takes refinery byproducts and processes them into a variety of road crack filling mixtures.

heat trace industrial heating and process controls 4
Chromalox designed a heat trace system for fuel and oil heating to prevent heat loss from the pipe and to maintain the crude oil at the proper temperature to keep it liquid and flowing.
aluminum metal processing heating
To prevent thermal shock from molten aluminum the tapping pots must be preheated.
wastewater processing heating and controls 2

Augers receive the heat they need thanks to Chromalox heat trace cables. Without freeze protection, the system could potentially have problems on start-up.

heat trace gutter ice controls
Chromalox custom designed a heat trace and control de-icing system to fit exact roof and gutter specifications.
metal dipping process heating and controls
Plating hangers, to which the metal items are attached and immersed in an acid plating solution, have to be plastisol-coated periodically to prevent expensive metal deposits on the hanger.
chemical processing systems
A manufacturer of specialty automotive fluids and lubricants located in the southeastern U.S. was in the process of transferring an existing production line to another facility.
solar energy process heating and controls
This solar energy producer uses hot oil and heat exchangers to heat various process materials in the manufacture of polysilicon for solar applications. 
textile industry process heating and controls 3
Impedance heating technolgy maintains uninterrupted process temperature during generator replacement installation.

Heating process for reactors and stills with hot tempering oils had limited temperature range.

gold mining industry heating and controls 3

When mining for gold, hazardous chemicals are held and heated within large storage tanks. Immersion Heaters with replaceable elements avoid the necessity and expense of draining tanks to maintain heaters.

Some cartridge heaters, such as this one, are constructed with a heli-arc welded end disc where small pin holes can form and lead to failure. 
train comfort heating 3
An OEM customer in railway car HVAC systems required both overhead heaters with open coil and tubular elements, as well as custom duct heaters to provide safe, reliable and comfortable heat on passenger railway cars.
commercial building heat trace
Chromalox self-regulating roof and gutter heating cable provides energy efficient solutions to roof ice dam problems in commercial buildings.
coal train
A Missouri coal-fired generating station needed to reduce coal dust in an onsite tunnel.  Approximately 9,000 rail cars of coal pass through the tunnel each month, dumping coal for power generation.
food warmers temperature controls

A global manufacturer and supplier of commercial equipment for many of the food service leaders needed a more efficient way to heat a new line of multilevel food warmers.

ice and snow heat trace

A colonial-style two-story municipal building in a Cleveland suburb was beset with build-ups of  snow, ice and moisture. 

satellite aerospace heating and controls
Chromalox Kapton® Flexible Heaters help simulate deep space conditions for terrestrial testing of satellites and other space systems.
water heater comfort heating and controls
Chromalox Kapton® flexible heaters help to provide consumers with clean and green on-demand water heating.
automotive industry painting process heating
Infrared lamps, used in an oven for about 18 years, required replacement about twice a year. 
metal chain
Steel chains must be "oil coated" to ensure lasting strength and rust-free delivery. 
auto seat
How does one heat, sense, and control a gel-filled, carbon fiber backed heated seat for a high-end luxury automobile?
industrial press process heating
Maintaining a temperature of 250° F on Micarta strips after after removal from a pre-heating oven.
electric motor machine tooling
A machining and tooling company was asked to retrofit an existing conveyor system that used a quartz bulb heating design in a two-stage oven.
Silicone Laminate Heaters provides more heat and saves more money.
metal grinder
One of the most critical production operations at this plant is the finish-grinding of the hubs and shafts for J57 and J75 jet engines.
salt mine process heating and controls
A Chromalox solution for maintaining correct temperatures in oil tanks for lightweight and thick viscous oil using an electric heat trace system.
power generation heating and controls 2
A large South Dakota electric power plant needed to upgrade the 10-year-old heating system on an external storage tank.
hot steel ingot

In this plant, the salt bath heating operation is initiated each working day at 3:00 a.m. by a time clock.

power generation heating and controls 3
A leading supplier of power generation and energy delivery technology needed to standardize the design of its various power turbines.
vacuform machine process heating
To heat thermoplastic sheet material for vacuum forming, heating must be rapid, uniform and controllable. 
eletronics industry metrology
Batch drying in a circulating hot air oven was slow and involved additional handling in loading and unloading.
laundry industry
A 50 feet oven using glass heat lamps gave an uneven paint bake. 
factory image
Chromalox heating specialists were called upon to keep mining safety showers from freezing. 
car grill automotive industry process heating
The auto manufacturer needed to quickly construct a paint baking oven large enough to handle one piece automobile grilles with a minimum of capital expenditure.
nuts and bolts
A protective, water-soluble oil is applied to the screws in a dip tank, then parts are conveyed through a furnace designed to dry off the water. 
dog food
Insect infestation was a serious problem at a dog food production plant. 
bottling industry process heating
To achieve a tight seat on bottle tops, wax liners are inserted and twisted into position. 
chocolate conveyor
The former method used by this food processor was to soften the candy by heating it with a gas burner prior to and during cutting and shaping. 
chemical reactor process heating and controls

Chromalox Hot Oil System maintains high temperatures necessary to heat jacketed reactors with customized seal-less pump.

metal plate process heating
This plant produces high quality metal work, some of which had been outsourced to a nearby painting company.
metal plate process heating
A low cost, accurately controlled oven for both drying and baking of painted products and printed circuits was required by this manufacturer. 
metal plate process heating
In this process, wood panels must be preheated before applying paint with an automatic coating machine.
petroleum industry process heating and controls 3
Chromalox helps southern California refinery heat products evenly. 
parts manufacturing assembly line
Parts are produced by the hundreds of thousands yearly and require fast cleaning to keep pace with the milling. 
heat trace paper processing heating and controls
A waxing system on an industrial packaging corrugated paper line could not reliably maintain the required temperature.
gutter heat trace cables
A large assisted living facility in Iowa had gone through several renovations and additions. 
asphalt pavement
Heating viscous fluids speeds loading time of tanker trucks.
railway comfort heating
Chromalox Silicone Laminate Heaters keeps passengers warm.
storage tanks
On tanks intended for outdoor installations, the original equipment manufacturer is often requested to install heating equipment. 
packaging process heating and controls
A manufacturer of packaging equipment for the poultry industry was unhappy with their current supplier of water tight elements for use on its machines.
laboratory equipment heating and controls
Chromalox Temperature Control Solutions for HVAC laboratory temperature problem
industry smokestacks
A world leader in the manufacture of smoke stack sampling equipment for power and process industries needed some help meeting EPA rules.
military marine heating and temperature controls
Working on a submarine in the depths of the ocean would be cold and damp without Chromalox radiant comfort heaters.
packaging industry process heating and controls
Chromalox packaged heating system provides tight control of temperature sensitive process.
Dolomite is composed of 60% calcium and 40% magnesium and tends to pick up moisture from rain and fog. The old method used was air drying which left them at the mercy of the weather.
electrical transformer
The numerous high voltage transformers located outdoors and on poles are constantly subjected to the heavily moisture-laden atmosphere. 
metal tubes
To safely heat a special asphalt for corrugated pipe coating in a tank semi-circular in cross-section was a particular challenge for this manufacturer.
tanks with piping
Resin stored in large kettles would solidify when the temperature dropped too low.
aircraft instrument panel
It was important for this aircraft manufacturer to provide heat tests for airplane altimeters to meet new Air Force requirements. 
rental construction industry
Chromalox blower heater is rugged and built to operate at various voltages without rewiring,
petroleum industry heating and controls 2

A Colorado natural gas driller performs hydraulic fracture drilling, using water and steam mixtures.

chemical industry process heating and controls
A worldwide leader in specialty chemical production has been using open coil duct heaters for many years to heat the air for some of its chemical applications.
parts washing immersion heater
Chromalox develops terminal enclosure that stands up to harsh operating environment and is easy to install.
confectionary food process and heat controls
Custom thick film heater provides improved heat transfer, as well as moisture resistance.
diesel generator heating
An load bank manufacturer was not receiving timely delivery of screw plug and straight tubular heaters from its current supplier.
heat trace industrial heating and controls 3
Turn-key heat trace system designdesigned using model SRM/E self-regulating heating cable.
camera lens world focus
A major web mapping service applications provider contacted Chromalox to come up with a unique flexible heater design for their land base and aerial earth mapping cameras.
chocolate molds process heating
For best results when molding chocolate, it is necessary to temper the molds to 90° F before filling with syrup.
zoo comfort heating
A Wyoming zoo’s plans for a new exhibit for mountain lions, lynx, otters, snow fox and grizzly bears called for keeping the animals as close to the public as possible. 
printing press image
In this lamination process, up to four sheets of paper are laminated at one time by a press.
agriculture industry process heating and controls
Chromalox helps OEM client in farming industries create custom machinery to dry out farming by-products such as corn husks and animal refuse into FDA approved fertilizer and other soil enrichments.
food processing heating
The cleanest and most efficient semi-automated system for deep fat frying of fish was desired by this customer. 
asphalt roller
No one likes to get up and go to work before the sun comes up in the morning, especially on cold winter mornings. 
alternative fuels process heating and controls
A Pennsylvania biofuels plant needed to find a new heat trace system to effectively protect its investment in the renewable energy future.  
heat trace industrial process heating and controls 2
The new laundry detergent manufacturing plant of a leading maker of household products required process temperature maintenance for its many process tanks and extensive piping. 
metal forging heating
With metal, the finishes required must be baked on, which meant they needed to install a baking oven.
lipstick beauty industry process heating
Keeping lipstick mixture at optimum temperature during forming process was difficult. 
food warmer temperature controls 2
This customer needed a temperature controller which was simple to use and available for quick shipment.
semi-conductor wafer production process heating and controls

All semi-conductor wafers, as part of their micro-fabrication, must undergo an etching process which chemically removes layers from the surface of a wafer during manufacturing.

hardwood flooring
The tremendous increase in building construction in past years and the wider use of laminated plywood has brought about an improvement in the art of making the plies for laminating into plywood.
canola oil production heating and controls
Chromalox helps 3rd party client design and install a heat trace system in a brand new canola oil processing plant to maintain specific process temperatures while flax seed is processed into canola oil.
church exterior
The previous method of heating the baptismal font use at a church was to draw hot water from church's hot water heating system.
Chromalox recycling support
During the re-plasticizing process of recycled plastics, the plastic materials need to be melted and the temperature accurately maintained throughout the process. Once the plastic is in a liquid form, petroleum and petroleum by-products can be harvested and re-used.
industrial injection presses
Accurate temperature control is a vital ingredient in plastic injection molding. 
fuel gas conditioning system heating and controls
Explosion-proof heat trace system provides safe, reliable freeze protection of pipes, valves, tanks in hazardous locations.
alternative energy wind turbine
Ensuring reliable operation of todays next-generation wind turbines has become a critical issue.
food processing - palm oil

Palm oil processing is being jeopardized by sudden temperature changes due to the increasing unpredictability of extremes in weather conditions around the globe.

Chromalox Chemical Industry Support
State legislature has mandated an increase in the amount of organic additives used in biodiesel fuels manufactured in Pennsylvania.
commercial food service heating controls
New UL 197 requirements create a challenge for a commercial cooking appliance manufacturer.
rubber pellets
De-burring the flashing from molded plastic parts is performed in a tumbler. Steam is used as a pickup medium for dust control.
Chromalox bottle sterilization
For accurate results, maintaining the temperature of hot water, used in thermal shock tests, at a constant temperature of 90° F above incoming cold water. 
biodiesel production heating and controls
Due to this caustic nature of the biodiesel production feedstock, this customer was experiencing process heater failures at a frequency that was unacceptable.
soybean industry process heating and controls
A Missouri food processing plant required an inexpensive heat trace system to prevent freezing on soybean oil processing pipe run. 
printing press image
Dry steam prevents excessive paper moisture in printing process.
automotive industry temperature controls
Weather stripping for automobile windshields, extruded of sun-resistant synthetic rubber, is produced in long strips, then cut to size, and spliced to be ready for installation on the auto assembly line.
heat trace chemical industry
The lubricant division of a major petroleum processor blends and packages motor oil and automotive lubricants, which are then shipped to retailers around the U.S. 
road construction painting process heating
Controlling the viscosity of asphalt paint is paramount to the quality of the end product.  
guitar manufacturing heating and controls

A manufacturer of custom guitars had a need to better control the lamination process for bonding the side panels that make up the guitar body shape.