Vacuum Feedthroughs, Heating Elements, and Custom Process Heaters for Aerospace, University Research, Semiconductor, Medical and OEM Applications

Air Process Heaters

Glass Rope

A fast responding electric heating element for liquids and gases used in clean processes, fuel cell development, bio-med applications, laboratory applications, food processing, pharmaceutical applications and other manufacturing processes. The heating elements can be exposed ni-chrome wire or isolated electrically from the process media, protecting them from contaminants and providing long life.

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Clean Gas and Liquid

Gas or liquid flows through an enclosed heated body and over internally sheathed heaters (the resistive elements are not directly in contact with the process media). All wetted parts are constructed of 304, 316, 321 stainless or other process compatible material, dictated by media. Heaters are designed to operate at high temperatures, and are available in wide range of custom wattages, watt densities, and voltages. Other options include many choices of process connections, internal temperature sensors, and wire terminations. Made in U.S.A.


Baking, drying, laminating, metal working, packaging, plastic welding, preheating, sealing, soldering, shrink fitting, synthetic fabric sewing, parts cleaning, critical fluid heating, solvent replacement, biomass extraction, bio reclamation, semiconductor processing equipment, photoresist material.

Backer Hotwatt
  • Define the volume of air or gas (SCFM) you will be heating.
  • Conclude the rise in temperature in degrees Fahrenheit (DeltaT in F).
  • Calculate the wattage required:
Air Heater
  • Take into concern the physical size necessities of your application and conclude from the specifications, the air heater best suited for your application. This can be either an exposed ni-chrome wire unit or a clean flow heater that has no exposure to chromium flaking. High watt densities are subject to approval due to the resistance and cable wire limitations.
  • For temperature control see section Temperature Control Console.

Standard Air Heater

Providing hot air and gas up to 540°C utilizing a “T” configuration with post terminal or leads. The copper tee is silver soldered to the stainless body with the outlet fitting typically heliarc welded. Ceramic coil supports a ni-chrome wire with standard pressure ratings up to 80 psig at room temperature.

Maximum Flow Heater

The nickel-chrome heating element is insulated with ceramic beads on a stainless steel support frame. This is affixed firmly to the inside of the tube designed for high volume, moderate temperatures with a 15 amp maximum and a 3.5 square inch cross sectional flow area.

Pure Flow Heater

Designed for applications involving clean air such as laboratories and environmental testing. The heat provided is non-contaminated air by way of passing over an enclosed surface typically 304 or 316 stainless steel instead of ni-chrome wire. This ensures no foreign substances will enter the heated air stream. The operating range is up to 15 CFM with temperatures up to 430°C.

Heavy Duty Heater

Higher temperatures of up to 650°C with flow rates in excess of 50 CFM. The heater is well suited for vacuum and pressure environments featuring a ni-chrome heating element with ceramic core and stainless steel welted fittings with ceramic-to-metal seals.

Serpentine Air Heater

Temperatures of up to 815°C with flow rates that are application specific (speak to BCE). The ruggedized construction is designed for long service life and can achieve up to 6KW (pending UL approval) can be installed horizontally or vertically.


The MCF heaters can be used to heat media in-line with the process flow. The heater is cleaned with IPA and rinsed with DI water and then passivated. This process minimizes contamination of the media being heated. For liquids, the max outlet temperature is driven by the liquid media, for gases the max outlet can be 800°C. The internal element in most cases comes with a built-in thermocouple (K or J), which will monitor the heater and the media temperature. BCE prefers grounded junctions, meaning grounded to the sheath of the internal heater. By having this configuration, the heating element is in direct contact with the media, hence maximum efficiency.

Mini Clean Flow - Hi-Wattage

Mini Clean Flow - Turbulent Flow Heater vs Linear Flow Heater

Download Graph (PDF)

Mini Clean Flow Turbulent vs Linear Heater Type Graph
Mini Clean Flow Turbulent
Mini Clean Flow Linear

Mini Clean Flow Heater Examples

Mini Clean Flow Heater Heater
Mini Clean Flow Heater Heater
Mini Clean Flow Heater Heater
Mini Clean Flow Heater Heater
Mini Clean Flow Heater Heater
Mini Clean Flow Heater Heater
Mini Clean Flow Hi Wattage


The Mega Clean Flow heater is a clean gas flowing unit used when applications required higher wattage and flow rates. This heater is used in the environmental testing labs, oil and gas, semiconductor processing, and food generation. A low watt density wire or rod style heater is built inside using a 304 or 316 stainless sheath. Some applications can handle up to 200CFM depending upon the outlet temperatures and pressure.

Duct Air Heater

The Incoloy and other material sheathed heaters are placed in a bundle in a high tensile strength cage for support. This sheath material and maximum watt densities based on the application, are used to reduce the footprint of the bundle thereby optimizing the size of the heater.

Application Help

All heaters whether Backer-Hotwatt or BCE will require application assistance and design. Specifications such as maximum amperage, maximum watts per linear inch of heated length, and wire watt densities are important. In addition, special features will be required with your inlet and outlet as well as the wattage required for your prototype or drop-in replacement.


BCE Engineering & Quality Assurance

BCE engineers provide decades of experience in design and development, delivering a wealth of empirical data and experience. BCE welcomes your custom requirement and will design and deliver a part that meets your challenging needs.

BCE is recognized for its commitment to quality and excellence by being certified in accordance with ISO 9001:2015.
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