Emission-free into the production of the future: Heat inductively!
In many industrial processes it is important to generate heat. Often, this heat must be available quickly and it must be possible to turn it off just as quickly. In addition, this heat must be distributed evenly and must be able to be controlled dynamically and according to demand. The heating should also require as little energy as possible.
With inductive heating systems from Kendrion you can replace traditional heating methods such as thermal oil, steam, or heating cartridges in industrial machines.
They enable consistent temperature control, maximum availability, and significant energy savings across all industries.
The induction heating systems are designed for manufacturing processes involving electrically generated heat. This includes applications in the plastic processing industry and the textile industry as well as drying processes in the paper industry.
Induction heaters are increasingly being used to heat the tools such as rollers, rolls or cylinders. Not only are they emission-free, they can also provide the heat quickly and switch it off again just as quickly. The inductive heat (up to 250°C) can be evenly distributed and allows dynamic control exactly as required.
Heating according to the eddy current principle
The technology is based on the eddy current principle, in which a magnetic alternating field is generated with the help of high-frequency alternating current, which is introduced into the metal in a defined manner. The resulting eddy current losses generate a thermal power that can be precisely dosed by changing the current flow. Due to the exact controllability of the temperature, the heating process can be reproduced exactly, which ensures a high quality of the process. The temperature is measured directly in the jacket with up to four measuring points. In addition, uniform heating is achieved by a multi-zone design of the surface and roller inductor.
Kendrion offers energy-optimised induction heating systems whose components are precisely matched to each other.
The Kendrion induction generators are designed as a modular system. They consist of a controller and up to 7 stackable induction generators. The controller can be integrated into the control of a machine via a fieldbus interface (e.g. PROFINET®). The control of the individual induction generators and the retrieval of status messages is carried out for all connected generators via the central controller. Depending on the configuration, the controller can also control the heating channels with integrated PID controllers. The units are designed for installation in control cabinets.
We support you from technical feasibility to series production!
RIGHT: Thermographic image of an inductively heated roller (©Kendrion)
By transforming your processes or plants to induction heating concepts, you are a pioneer and a visionary. Not only does the heating process become more climate-friendly, but above all you achieve an increase in productivity and the quality of the end products.
With Kendrion, you have a partner at your side who not only specializes in the production of induction heaters, but also has extensive expertise in planning and design.
What services does Kendrion offer?
A core competence of Kendrion is numerical simulations of magnetic as well as fluid and thermodynamic processes. With our analysis tools, we can model even complex processes and design them with high precision. This enables us not only to evaluate the success of feasibility studies and preliminary developments, but also to produce concrete designs and samples as well as the final series product.
We are happy to provide support both in an advisory capacity and in the active solution of technical problems.
Our services include in detail:
Perform a joint process analysis
Set up functional specifications
Developing conceptual solutions
Creation of the design
Selection and adaptation of the induction generator
Development of the inductor
Realization of the series production
What are the advantages of induction heating?
What are the advantages of induction heating?
Temperature, heating time and heat pattern are reproducible. With inductive heating systems, you can convert 90% of the expended energy into usable heat without burning fossil fuels. Process temperatures are reached in a very short time for typical workpieces thanks to high surface power and low masses. By designing the inductors and using multiple heating zones, a very precise surface temperature can be achieved, while the entire heating process can be controlled by induction generators and process control software.
What are the advantages of inductive heating compared to the use of electric heating cartridges?
What are the advantages of inductive heating compared to the use of electric heating cartridges?
Induction heating generates heat directly within the metallic component instead of transferring it from an embedded heating element. This eliminates typical limitations associated with cartridge heaters and improves overall process stability.
Compared to electric cartridge heaters, induction heating offers the following advantages:
Faster heat-up times: Higher power density and direct heat generation within the workpiece enable significantly shorter start-up times. Thermal contact resistance between heater and component is eliminated.
Improved heat transfer efficiency: No air gaps or imperfect contact surfaces that can reduce performance in cartridge heater applications.
Precise temperature control: Power can be regulated accurately, allowing stable and reproducible temperature profiles for demanding industrial processes.
Reduced maintenance effort: No risk of cartridge heaters seizing in drilled holes and no complex removal procedures in case of failure. Inductors are typically easier to access and replace.
Lower risk of local overheating: Heat is generated uniformly within the component, reducing hot spots and improving process reliability.
Reduced thermal stress on surrounding components: More controlled heat input increases the service life of adjacent machine parts.
By combining direct energy input, improved controllability and lower maintenance requirements, induction heating represents a reliable and efficient alternative to electric cartridge heaters in industrial applications.
What are the advantages of induction heating compared to the use of gas heaters?
What are the advantages of induction heating compared to the use of gas heaters?
Induction heating generates heat directly within the workpiece without combustion and without fossil fuels. This significantly improves energy efficiency and enables cleaner, more controllable industrial heat processes.
Compared to gas-based heating systems, induction heating offers the following advantages:
Lower energy consumption: Direct heat generation within the component can reduce energy demand by up to 50%, depending on the application.
Reduced CO₂ emissions: No gas combustion means no direct emissions. When powered by renewable electricity, the process can operate with a very low carbon footprint, resulting in a solution that is not only cost-efficient but also environmentally friendly.
Higher efficiency: No energy losses from exhaust gases, burners or flame-based heat transfer.
Precise controllability: Power can be regulated from 0–100% in 1% increments, enabling accurate temperature control and improved process stability.
Improved safety: No open flames, no gas lines and no risk of gas leaks, significantly reducing operational hazards.
Clean operation: No combustion residues, no flue gases and reduced thermal impact on surrounding components.
By combining energy efficiency, emission reduction, precise control and enhanced safety, induction heating represents a future-ready alternative to gas heating systems in industrial applications.
What are the advantages of induction heating compared to the use of thermal oil heaters?
What are the advantages of induction heating compared to the use of thermal oil heaters?
Induction heating eliminates the need for a heat transfer medium and generates heat directly within the component. This significantly reduces energy losses typically associated with thermal oil systems, such as heating large oil volumes, pipework losses and external tempering units.
Key advantages compared to thermal oil heating include:
Higher energy efficiency: No heat losses in oil circuits or piping. Energy is converted directly into heat within the target material.
Precise controllability: Power can be regulated from 0–100% in 1% increments. Individual zones, such as sections of rollers or tooling surfaces, can be controlled independently.
Faster heat-up times: Direct heat generation without thermal transfer resistance enables shorter start-up times and increased productivity.
Compact system design: No bulky tempering units, pumps or oil piping required, making integration easier in space-constrained machinery.
Reduced maintenance effort: No oil changes, no leakage risks and no disposal of used thermal oil.
Improved safety and cleanliness: Eliminates contamination risks caused by oil leaks and reduces operator safety hazards.
By combining higher energy efficiency, improved process control and lower maintenance requirements, induction heating can significantly reduce total cost of ownership compared to thermal oil-based systems.
