High Power Induction Heaters | 95% Energy Efficiency | Stiefel

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Stiefel's High Power Induction Heaters - Forged for Exceptional Performance for Extensive Heating

Stiefel’s high power induction heaters deliver 50–500 kW range, high repetitive precision with 5–500 of electric machines, with peak performance precision within millimeters.
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Benefits of Stiefel’s Induction Heater Systems

For Precise Control of Body Temperature: Ultra Magnetic Heating

Compared to resistance heating, power consumption with Stiefel’s induction heaters is considerably lower. The use of modern electromagnetic technology offers energy efficiency of upto 95%. Solid state inverters produce high frequency magnetic fields (20-400 kHz) which heat conductors directly with minimum heat loss. A Chinese automotive plant reduced the time required to heat engine components from 30 minutes to 8 minutes with our 50kW induction heater, saving energy costs by 40%. The accurate measurement of the temperatures (±1°C) guarantees consistent heating which is important for processes like metal forging and plastic extrusion.

Wide Scope of Use for Different Industrial Processes

From research laboratory to big industrial lines, our induction heaters are designed to suit use at varying processes and materials. They have modular coil designs that can be adapted for different shapes, flat, cylindrical or even irregular. Power output ranges from 5kW to 500kW. A german aerospace manufacturer applies our 200kW heater for brazing titanium components because he can get consistent joint strength without overheating. In oil refineries, pipe welding is done continuously, and water cooled transformers and heat exchangers allow 24/7 operation in high duty cycle modes.

Safe and Dependable Function with Cutting Edge Protective Features

Stiefel implements safety features escaping EMI like overvoltage protection, thermal overload sensors, and grounded shielding. Stiefel's enclosures marked IP65 are also resistant to dust and moisture making them ideal for rugged factory settings. With emergency stop mechanisms and interlock systems for induction heaters, operators' accidents were reduced by 85% in a Japanese electronics plant. Inter diagnostic systems also warn technicians about potential issues such as coil degradation or failures in cooling systems.

Maintenance Economically Efficient and Equipment Longevity

Induction Stiefel heaters are built with copper nickel coils and aluminum nitride insulators which in turn boosts overall product lifespan alongside reduced maintenance to over 10 years. Modular units in a U.S. steel mill’s annealing line can be replaced swiftly, reducing downtime by 50%. Induction heaters are devoid of moving parts which minimizes wear leading to an annual reduction of maintenance costs by 30% compared to gas fired systems. Stiefel also offers retrofitting services to upgrade legacy heating systems which enabled a Dutch recycling plant to harness old resistance heaters to induction with a 2 year payback period.

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Stiefel high power heaters are indented for heavy-duty industrial work. The modular coil structure makes it much easier to accommodate to large workpieces due to its flexible geometry. The sophisticated control of the system guarantees real-time adjustment to power delivery to maintain the set temperature. For a German aerospace client, our 200kW heater improved the production throughput by 30 percent reduction of forging time for titanium components, enabling sharper production flow. Standard features include over-temperature protection, automatic shut-off during faults and other safety features.

Frequently Asked Questions

What is the major difference between induction heating and gas/electric heating?

Induction heating is faster by up to 5 times, more efficient (95% vs. 60-70% of gas), and has better control of temperature. It also has no direct emissions, making it preferable for gas-cleaning environments or areas with strict carbon policies. For example, a Canadian food processing plant started usingour induction heaters for sterilization, which reduced CO2 emissions by 60% and, at the same time, increased throughput by 35%.
We do specialize in heaters designed for non-metallic materials. Induction heating is mostly focused on conductive materials, such as steel alloy, aluminum, and copper. For example, is a Spanish plastics factory, our induction heaters are used to preheat metallic molds which they use to pour plastic resins. The result is they are able to achieve uniform melting of ±2°C, which wastes less energy compared to direct heating of the plastic and reduces material degeneration.
They are compliant with CE, UL, and CSA, which includes EN 61010 for electrical safety and EN 50598 for EMC. The ATEX-certified (Zone 2 hazardous areas) models are used in LPG processing plants, where their spark-free design eliminates fire hazards. Every unit is put through extensive testing, such as continuous 1,000-hour operation tests and surge protection simulations. These units are tested rigorously.
Of course. Our engineering staff creates systems tailored to the specific needs of the customers. With a Swiss medical device company, we developed a 10kW induction heater designed so a flexible coil could heat tiny stainless steel parts not easily accessible. Custom projects, including on-site testing and prototyping, take around 8-12 weeks.

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Customer Reviews

Li Ming
The Best Thing That Could Happen to Our Forging Line

Stiefel’s 150kW induction heater literally changed the way we forged metal. Material savings from efficient processes, for example, heating metal to 1,200°C in 120 seconds, with precise temperature control, reduced waste by 25%. Water-cooling systems allow for non-stop operation during peak production, and IoT remote monitoring aids in energy optimization.

Jens H.
Safe and Reliable for Hazardous Environments

Ensuring workplace safety is very critical in our chemical plant. The ATEX induction heaters from Stiefel have completely gotten rid of the gas combustion fire dangers. The functionality of emergency stop controls, low EMF emissions, and the grounded shielding also calm my worries. The shielding meets the law precise workplace EMF emission limits for occupational health and safety.

Sarah L.
Cost-Effective Retrofit for Our Aging Systems

The company’s three factory resistance heaters were upgraded to Stiefel’s induction models and, quite frankly, the factory members were quite shocked to discover a decreased energy cost by 38%. The team's training sessions for our technicians and the broad from- start-to-finish induction installation approach Stiefel’s brought were remarkably efficient and unbelievably easy. Stiefel’s offers a smart choice with low maintenance, long lifespans, and reduced painted over plant living expenses.

Akiko S.
Precision Heating for High-Tech Manufacturing

The precision I take constructing the semiconductor production line components is extreme. Balance of fragile pieces relies on stringent standards Steifel’s 5kW induction heater with micro-coil provides; delivers no greater than and no lesser than ±0.5°C precision. Also, the compact design blends into the overhead tight production layout space while coil size variation ease of access quick change adaptability on various part sizes increases.

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Cutting-Edge Energy Efficiency

Cutting-Edge Energy Efficiency

Stiefel’s induction heaters lead the industry with 95% energy efficiency and solid-state electric structure. A U.K auto supplier transitioning to our 100kW model saved £22,000 in yearly energy costs. Stiefel’s heater paid for itself in 18 months.
IoT-Enabled Smart Control

IoT-Enabled Smart Control

Our heaters come with integrated IoT modules that relay real-time temperature, power, and maintenance data. A French aerospace facility used this data to anticipate coil replacements that preemptively reduced unscheduled downtime by 40% and increased OEE by 25%.
Global Engineering Expertise

Global Engineering Expertise

Stiefel’s R&D has over ten years of experience designing solutions for the automotive, aerospace, and other industries, and their work is supported by a global service network providing 24/7 technical support for challenges posed by different regions and customized induction heating applications.