TUTCO CONDUCTIVE

Mineral Insulated (MI) Better Band Heaters

TUTCO Mineral Insulated Band Heaters are designed for applications demanding consistent, high process temperatures. The TUTCO MI Better Band, equipped with Alumina Oxide insulation, delivers a maximum watt density of 80W/in². Constructed from high-quality materials, it can sustain temperatures up to 1400ºF (760ºC), depending on the application.

REQUEST A QUOTE

Mineral Insulated (MI) Better Band Heaters Image

FEATURES AND BENEFITS

High temperature up to 1400ºF (760ºC)
480V MAX (AC or DC)
Easy customization
Maximum high watt density 80W/In²
Alumina Oxide Insulation
Stainless steel band
Rugged lead protection
Custom designed to specifications required
Low minimum order requirements
Expedited order options are available
Consult factory for other custom options

TUTCO does not recommend leads for temperatures above 900º max due to wire temperature rating.

Specifications
Maximum Operating Temperature	1400°F (760ºC)
Holes	Yes
Cutouts	Yes
Durability	Excellent
Power	80 Watts/in² max (12.4 Watts/cm² )
Wattage Tolerance	+5% / -10%
Available Voltage	480V max (AC or DC)
Voltage option for Dual Phase	120V/240V or 240V/480V (AC or DC) Three Phase - Wye or Delta
Resistance Tolerance	+10% / -5%
Wattage Tolerance	+5% / -10%
Inside Diameter Range	3/4” ± 1/32” to 30” ±1/16” (19.1mm to 762mm)
Width Range	3/4” ± 1/16” to 6” ±1/16” (19.1mm to 152mm)
Holes, Slots, and Cutouts	3 max (dimension tolerance of +1/16” / -0”)

APPLICATIONS

PLASTICS

Extruders & Extrusion Die Heaters
Plastic Injection Molding
Injection Molding Nozzle Heaters
Blown Film Processes
Blow Molding Machines

AGRICULTURE

Holding Tanks
Drum & Barrel Heating

FOOD SERVICE

Food Processing
Candy Extruders
Food Service Warming

PROCESSES

Chemical Processing
Tin and Flux Melting
Scientific Testing Equipment
3D Printers
Medical Process Heater

In addition, Mineral Insulated Band heaters can be modified to meet the demands of virtually any special application. Our engineers can utilize a variety of alternative features and options to customize the heater to your specific needs.

Mineral Insulated (MI) Better Band Heaters Application Image

LEAD OPTIONS

FLEXIBLE LEADS, NEAR GAP

ON THICKNESS,
EACH SIDE OF GAP

ON ONE SIDE OF GAP

ON TOP, ONE NEAR GAP,

Available with leads exiting axially or along the width of the band. Axial leads can be positioned on each side of the gap or on one side only. Axial leads feature full contact clamping for longer heater life. 10″ (25.4 cm) leads standard, other lengths available.

FLEXIBLE LEADS, NEAR GAP, WITH CAP

ON TOP, NEAR GAP WITH CAP AND 90º TUBE

Low profile cap and tube with leads exiting axially, 90° to axis, or at a specified 15°, 30°, or 45° from axis. Axial leads exit in direction of junction/termination. If heaters are in tandem, they can be positioned next to one another. 90 degree cap ideal for installations where access is limited. 10″ (25.4 cm) leads standard, other lengths available.

TWO PIECE BAND
Specify for easy installation/removal where projections or tandem positioned heaters are in use. When using two-piece heaters, each half is designed with half of the total wattage requirement. This has the capability of being used on either 120 Volt (V1 = V2 = V Total) when connected in parallel or 240 Volts (V1 + V2 = V total) when connected in series.

GROUND WIRE
A ground wire is available on most heaters where grounding is required.

Additional Lead Options:
FLEXIBLE LEADS, OPPOSITE GAP

ON THICKNESS,
OPPOSITE GAP

ONE PIECE ON TOP,
OPPOSITE GAP

The cap and tube option gives protection near the sheath. Leads can exit axially, 90° to the axis, or at a specified 15°, 30° or 45° from the axis. 10″ (25.4 cm)lead standard. Other lengths available.

SCREW TERMINATION OPTIONS

SCREW TERMINALS NEAR GAP

ON TOP, NEAR EACH END
ON GAP

ON TOP, ONE PLACE NEAR GAP, ALONG LENGTH

ON TOP, ONE PLACE NEAR GAP, ALONG WIDTH

Screw terminals can be positioned near the gap on each side, along the width, or along the length. This style of terminal helps simplify lead wire connections.

SCREW TERMINALS OPPOSITE GAP

ON TOP, OPPOSITE GAP,
ALONG LENGTH

ON TOP, OPPOSITE GAP,
ALONG WIDTH

Screw terminals can also be positioned opposite the gap either along the width or along the length.

LEAD PROTECTION

PLAIN LEADS
Our high temperature mica insulated leadwire with nickel standard conductors is suitable for continuous service up to 842°F (450°C).

SLEEVING
Fiberglass silicone rubber coated sleeving class C1, 392°F (200°C) service. Provides extra insulation where wire is exposed to heat, molten plastics or abrasion. Rated for 1500 volts at 428°F (220°C), except 5/16" size which has no voltage rating.

STAINLESS STEEL BRAID
Stainless steel over braid is most commonly specified in applications where leads may be subjected to abrasion due to movement of the application. Lead wires may be rubbing together or passing over sharp objects.

STAINLESS STEEL ARMOR
Used over leads in areas where more protection is necessary. Selected for similar applications as the stainless steel braid, in addition to applications where non-fluid contamination may come in contact with the leads. This lead protection is not as flexible as the braid. Stainless steel square lock construction.

CONVOLUTED ARMOR
This is a seamless product and can be attached to the heater so that fluids do not contaminate the leads. This system of lead protection is generally associated with the Sealed Band construction. Not recommended where leads are flexed in the application.

COPPER ELBOW
Simple straight abrasion-resistant stainless steel armor or moisture-resistant armor is attached to a 90° copper elbow to accommodate applications where lead access is only possible from one side and armor exit direction is a concern. When ordering without a swivel option, specify direction of 90° copper elbow.

PIPE COUPLING/EXTENSION TUBE
These pipe couplings, welded to the heater sheath, provide a method of fastening conduit or armor to the heater which can be disconnected from the heater as required. Standard stainless steel.

STANDARD TERMINATION BOX
Designed for protection safety, snap-off cover leaves terminals easily accessible.

SHAPES AND CONSTRUCTION

HINGED BAND
Available in two-piece heaters for applications in which the assembly is frequently required to be opened for easy and registered positioning around the surface.

EXPANDABLE BAND
A heater which can be easily expanded to fit around a surface. Not for applications requiring consistent removal. (2-3 times max.) Can be expanded 2-3 times without parting.

PARTIAL BAND
Available in a variety of terminations and clamping styles (please indicate when ordering). Specially constructed to any angle. Please specify inner diameter, width, angle and termination style.

SPECIAL WITH HOLES
Heaters can be built to satisfy your special requirements. Certain applications require holes for thermocouples, to clear tubing, wiring, and other obstacles. These modifications require customer drawings to specify exact diameters and locations of the holes. Special order only.

SPECIAL WITH CUTOUT
When clearance is a problem with band heater installation, consider requesting slot cut-outs. This can greatly facilitate installation. Drawing is required with exact dimensions and locations. Special order only. Specify length, maximum length: 12″ (30 cm).

PLUGS

GERMAN POWER PLUG OPTIONS

GERMAN PLUG

GERMAN PLUG WITH BRACKET

GERMAN PLUG WITH BOX

The German Power Plug is illustrated in the most common position. There are occasions for special boxes where the plug may be positioned on the top surface of the box.

OTHER PLUG OPTIONS

QUICK DISCONNECT SOCKET
2 POLE, 25 AMP, 250V, 600°F (315°C) Service. Ideal for power connection to heaters. Durable cast aluminum body on female side. Both side have ceramic insulators. Ground connection via contact fingers.

SPECIALTY PLUGS
Customer to specify manufacturer, type, part number, and amperage required.

CLAMPING

STRAP STANDARDS

Straps and strap ends can be vastly modified to fit a wide variety of bands. As wider bands are used, multiple straps will most likely be designed in. Normally barrel nuts are built into the ends: one threaded, one through hole. Slots shown are to clear termination areas. Unless otherwise specified, straps are assigned by our engineering staff to best suit each application.

ONE-PIECE STRAP

TWO-PIECE STRAP

STRAP

STRAP ENDS

EAR CLAMPING

BAR CLAMPING

Illustrated are the various available styles of clamping for band heaters. When a band is provided the material is of a low coefficient of expansion type. Width of the clamping band or the number used per heater is dictated by the design standards. There are a variety of clamping mechanisms that can be attached to the band or directly to the heater. The most common forms are the strap and strap ends. Factors influencing the type and size of clamping are:

• Type of band heater
• Diameter and Width
• Termination type and location
• Holes and notches in heater
• Preferences of the user

Consult factory for other custom options

BELLEVILLE SPRING WASHER CLAMPING
A clamping system is generally selected for use with large diameter heaters where additional compensation of band elongation is required. Belleville clamping comes with a standard 1/4–20 X (12.7 cm) long screw.

SPRING BOLT CLAMPING
Spring bolt clamping applies constant tension on the clamping mechanism to compensate for heater elongation once it has been energized. Spring bolt clamping comes with either a 1/4–20 X 4 (10.7cm) or 1/4 – 20 X 5â€³ (12.7cm) long screw.

TURNBUCKLE
Specified where a heater is used to heat an I.D. surface. Use of this mechanism is governed by the heater diameter and width. Obstructions such as shafts passing along the center line of the heater may present an interference problem.

WEDGE-LOCK
Specially designed for mounting where space is limited. Eliminates the need for straps. Leads must exit opposite gap.

RESOURCES

Frequently Asked Questions

What customization options are available for the MI Better Band?

TUTCO can engineer the MI Better Band to meet specific process or equipment requirements. Options include custom diameters, widths, wattages, and voltages (up to 480 V AC or DC). A variety of lead terminations, protection styles, grounding methods, and clamping configurations are available to suit your installation and environmental conditions. Low-volume and expedited production options are also supported.

What applications are best suited for the MI Better Band Heater?

These heaters are designed for high-temperature, high-watt-density industrial applications, such as extrusion barrels, die heads, blow molding, injection molding, chemical processing, and drum heating. The MI construction makes them well suited for environments where traditional mica bands may fail due to heat, vibration, or contamination.

What are the advantages of alumina oxide insulation?

Alumina oxide (Al₂O₃) is an advanced ceramic material known for its excellent heat transfer and electrical insulation properties. In the MI Better Band, it enables tight thermal coupling, minimizes heat loss, and ensures uniform temperature across the heater surface. This insulation also supports faster heat-up times and improved energy efficiency under demanding thermal loads.

What makes the MI Better Band Heater different from standard mica band heaters?

The MI Better Band uses a mineral-insulated (MI) construction with alumina oxide insulation, which provides superior thermal conductivity and dielectric strength compared to traditional mica. This design allows for much higher watt densities—up to 80 W/in²—and operating temperatures up to 1400°F (760°C). It’s ideal for high-temperature processes where precise, consistent heating is required.