Improving Circulation Heater Efficiency: A Simplified Guide

The superior efficiency of circulation heaters is one of the main reasons they are so popular. Heater efficiency improves the reliability, cost-efficiency, and production rate of any project. As such, it’s important to maximize the efficiency of your circulation heater.

This simple guide provides easy and clear tips on how to improve circulation heater efficiency for your project(s).


In all industries, automation has become king when it comes to efficiency. By removing manual tasks from operations, automation increases the accuracy and responsiveness of controls while decreasing staffing needs and resources.

Digital control panels provide automation for circulation heater systems. They are the brain of your heating system, connecting all controls, monitoring, and safety devices in one place. Using automation allows the control panel to make decisions faster and monitor circulation heating systems with greater accuracy. As a result, they make the entire system more efficient and reliable.

Electric Versus Gas Power

Circulation heaters tend to use either electric or gas power. Although gas was once the standard, industries are making the switch to electricity. Electric circulation heaters offer significant advantages over fossil fuel heaters.


One of the big advantages of electric industrial heaters is their simpler design. Gas heaters have more moving parts and complex designs. Combine that with ongoing internal combustion and they end up with shorter lifespans, reduce efficiency faster, and break down more often.

The simplicity of electric circulation heaters prolongs their lifespans while ensuring they maintain optimum efficiency for longer. They are easier to maintain, inspect, and repair. As such, they are not only more efficient but also more cost-effective over their lifespan.


Electricity itself is also a more efficient power source. There is virtually no waste with electric heaters, whereas fossil fuels waste significant power in both transportation and operation. As a result, they end up costing more to operate long-term.

As well, electric heaters have faster starts and are capable of achieving higher temperatures faster than fossil fuel alternatives.


Proper installation and maintenance of industrial heaters are essential for long-term efficiency. Regularly scheduled maintenance makes it possible to identify issues before they become a problem, so you can rectify them without interrupting workflow or causing unnecessary damage.

Look out for signs of circulation heater fouling such as scaling, coking, sedimentation, and organic growth. Regular flushing is a simple way to reduce or prevent many of these problems quickly and effectively.

A well-maintained circulation heater not only lasts longer but continues to operate at optimal efficiency throughout its lifespan.

Insulation & Seals

Common causes of heat loss, leaks, and reduced efficiency stem from problems with insulation and seals. Where seals and gaskets are an improper fit or become loose, debris can enter the system, fluid can leak out, and the heating system runs less efficiently. Choosing the right types of seals and gaskets helps to ensure a better fit, as well as inspecting them during maintenance.

Insulation is essential for preventing heat loss, reducing the stress on circulation heaters and allowing them to operate less frequently. As a result, the operating costs of the heater are reduced, and the heater lasts longer.

Custom-Manufactured Circulation Heaters Maximize Efficiency

Wattco custom manufactures electric circulation heaters for any industry and project. Our engineers match the heater, design, and configuration to your specific project and budget. As a result, you get a circulation heater with the best efficiency and reliability available.

Contact Wattco today for electric circulation heater quotes and information.

Latest blogs

Common Industries that Wattco works with

Case Studies View All

Why is Mineral Oil Used in Thermal Heaters?
Thermal heaters, also known as thermal fluid heaters, employ the use of a thermal liquid such as wat...
Read More..

What to Use When Heating Wax
SituationA popular chemical compound that often requires heating is wax, which is an organic compoun...
Read More..

What is Passivation? Why do We Need to Passivate Flanged Heaters?
  Most of the parts of flanged heaters are made of stainless steel—an alloy that is mainly compri...
Read More..

What is a Digital Controller?
Control panels are essential elements of any electrical device. Control panels are especially i...
Read More..

Vegetable Oil Heating
Food Industries and Vegetable Oil Viscosity In Cleveland Ohio, a large food manufacturer called WATT...
Read More..

Wattco News View All

Over-The-Side Heaters for Plating Tanks
For bonding and coating metals or plastics, the plating process occurs in tanks. The two types of he...
Read More..

Join WATTCO At The 50th Anniversary Global Petroleum Show!
Wattco invitation...
Read More..

Tank Heaters for Shale Gas Storage
The shale boom in the USA has hit peak productivity. While Americans enjoy the benefits of plentiful...
Read More..

Renewable Natural Gas-A Step Change Towards Clean Energy
The world has shifted focus to reducing greenhouse emissions and introducing carbon-neutral and carb...
Read More..

Industrial Immersion Electrical Heaters and their Industrial Applications
Industrial immersion electrical heaters have a number of industrial applications. These heaters are ...
Read More..

Most Popular Blogs View All