IntegroWrap
THE THERMAL WAY
PROCESS HEATERS
CIRCULATION HEATERS
About us
Integro Process Heating Solutions is a technology-led, engineering-driven company founded by Mr. Anil
Kumar Tufchi, a veteran with over 30 years of domain expertise in power systems, renewable energy,
comfort heating, food dehydration and industrial heating solutions. From humble beginnings in diesel
genset trading and acoustic enclosure fabrication, Mr. Tufchi’s passion for thermal systems led to
innovations in solar energy, process heating, and specialized drying systems. This journey finally laid the
foundation for Integro Process Heating Solutions—an organization committed to delivering high-efficiency,
high-reliability heating technologies.
With deep field experience, strong technical foundations, and a solutions-first approach, IPHS designs and
deliver high-performance thermal heating systems & solutions that boost productivity and optimize
operational costs.
Description & Functionality
Circulation heaters, also known as in-line heaters, are one of Integro ‘s core offerings in the field of industrial
heating solutions. These heaters are designed to heat liquids or gases as they flow through a closed-loop
system, making them highly efficient and ideal for continuous process applications. These units are
deployed where precise thermal control, rapid heat transfer, and compact footprint are required.
Design & Construction
• Heating Elements: Low or medium watt density tubular elements (Incoloy®, SS304/316, copper,
titanium), selected based on the thermal characteristics of the fluid (e.g., viscosity, flash point,
corrosiveness).
• Pressure Vessel: Fabricated as per ASME Sec VIII Div 1, IS 2825, or customer-specified codes. Materials
include carbon steel, SS316/SS304, duplex stainless steel, and special alloys for aggressive media.
• Flow Path: Engineered for turbulent flow regimes to enhance heat transfer and prevent element burnout.
Internal baffles available for optimized velocity profiles.
• Nozzles: Flanged or threaded inlet/outlet nozzles designed per ANSI B16.5 standards. Optional thermowell
ports, drain/vent nozzles.
• Insulation & Cladding: High-efficiency mineral wool or ceramic blanket insulation, with aluminum or SS
cladding for minimal heat loss.
At Integro, we specialize in custom-designed circulation heaters, engineered to meet the specific
temperature, pressure, and flow requirements of diverse industries.
Key Features
High Energy Efficiency: Direct immersion of heating elements in
the process fluid ensures minimal heat loss.
Precise Temperature Control: Equipped with advanced
temperature sensors and controllers for accurate heat
regulation.
Robust Construction: Built from stainless steel, carbon steel, or
exotic alloys depending on the process medium.
Skid-Mounted Options: Integrated systems with pumps, valves,
insulation, and control panels for plug-and-play installation.
Safety Assured: Includes pressure relief valves, thermostats,
and over-temperature protection mechanisms.
CIRCULATION HEATERS
Customization & Engineering
At Integro, every circulation heater is custom-engineered to match your
process requirements. We work closely with clients to understand:
• Required flow rates and operating pressure
• Desired outlet temperatures
• Type of process fluid
• Mounting and piping requirements
Our in-house engineering team ensures optimal thermal performance,
long operational life, and easy integration with your existing systems.
Control & Instrumentation
Thermocouples / RTDs:
For feedback to temperature controllers or PLCs.
Temperature Control Panels:
Options include digital PID controllers, thyristor-based SCRs,
and PLC/SCADA integration.
Safety Features:
• High-limit thermostat or digital over-temperature cut-off
• Pressure relief valve (optional)
• Flow interlock switches
• Earth leakage protection (ELCB/RCD)
Technical Specifications (Customizable per application)
Parameter Range/Option
Power Rating 2 kW to 500 kW+
Operating Voltage 230V / 415V / 690V AC, 50/60 Hz
Design Pressure Up to 10 bar (higher on request)
Design Temperature Up to 450°C
Fluid Compatibility Water, oils, air, nitrogen, solvents, etc.
Mounting Orientation Horizontal / Vertical
Protection Rating IP55 / IP65 (standard), Ex d / Ex e on request
Advantages
• Compact, skid-based designs reduce installation complexity
• High turn-down ratio with thyristor control
• Zero emissions; ideal for clean energy applications
• Fully engineered packages with flow, temperature, and
pressure controls
Custom Engineering Services
Integro offers end-to-end design, engineering, and fabrication
services for circulation heaters:
• Electrical load calculation and selection
• Skid integration with pumps, control panels, and sensors
• Documentation: GA drawings, QAPs, FAT protocols, and IOM manuals
IMMERSION HEATERS
Purpose and Operation
Immersion heaters are electric resistance heating devices designed to transfer thermal energy directly to a
liquid or semi-solid medium. By immersing tubular or cartridge heating elements directly into the process
fluid, they eliminate heat transfer losses and offer highly responsive temperature control.
These units are primarily used in closed or open tanks, pressure vessels, reservoirs, or pipelines for fluid
temperature maintenance, preheating, or melting applications in continuous or batch processes.
Construction Features
A. Heating Elements
• Type: Heavy-duty, low or medium watt density tubular elements, designed to reduce sheath surface
temperatures and prevent localized overheating.
• Materials:
• Incoloy® 800/825 – For high-temperature or mildly corrosive fluids
• SS316L / SS304 – For water, mild chemicals, and food-grade applications
• Copper – For clean water or low-temp heating
• Titanium / PTFE-coated – For highly aggressive chemical environments
• Watt Density: Ranges from 5 to 30 W/cm2, calculated based on fluid type, thermal conductivity, and
viscosity. Lower densities are selected for viscous or thermally sensitive materials (e.g., bitumen, oil).
B. Mounting Options
Type Description
Welded to ANSI/ASME/BS flanges (DN25–DN300),
Flanged Type
suitable for pressurized tanks and high
power applications
Threaded connections (1"–3" BSP/NPT),
Screw Plug Type
compact form factor for localized heating
Non-permanent installation into open tanks;
Over-the-Side
suitable for temporary or mobile use cases
C. Sheath and Tube Characteristics
Parameter Range / Specification
Tube Diameter 8.5 mm, 10 mm, 12.5 mm (typical)
Sheath Thickness 0.45 – 0.8 mm
Bending Radius As per IEC 60335 / IS 4159 standards
Surface Finish Bright annealed or electropolished (on request)
Electrical and Control Features
• Operating Voltage: 230V, 415V, 1Ph/3Ph, 50/60 Hz
• Power Ratings: From 0.5 kW to 500 kW (modular banks for higher loads)
• Control Options:
• Built-in thermostats (capillary, bi-metallic)
• RTDs / Thermocouples integrated into thermowells for external PID control
• Solid-State Relay (SSR) / Thyristor-based SCR control for high-precision thermal cycling
• Protection Ratings: IP55 / IP65 standard. Flameproof enclosures (available on request)
IMMERSION HEATERS
Thermal Design Parameters
Parameter Value / Range
Maximum Sheath Temp. Up to 800°C (depending on sheath material)
Operating Fluid Temp. 5°C to 550°C (application-dependent)
Design Pressure Up to 35 bar (for flanged versions)
Fluid Compatibility Water, mineral oils, synthetic oils, glycols, caustics, solvents, etc.
• Thermal Expansion Compensation: Designed with adjustable compression seals or spring-loaded
assemblies for high-cycling applications.
• Element Redundancy: Multi-element banks designed with isolated circuits for partial load
operation or standby modes.
Applications by Industry
Industry Application Area
Oil & Gas Fuel oil preheating, transformer oil heating
Chemicals Acid and alkali bath heating
Pharmaceuticals Jacketed tank fluid heating, solvent temperature control
Power Generation Lube oil heating, turbine oil conditioning
Food & Beverage Edible oil, syrup, chocolate melting and heating
Marine Bilge water, fuel conditioning, and tank heating
Advantages
• Direct thermal transfer with >98% efficiency
• Minimal footprint for high-power density systems
• Precision control via integrated temperature feedback and PLC/SCR
• Custom-engineered solutions for material compatibility and process integration
• High reliability in continuous and cyclic duty conditions
Engineering & Quality Compliance
Design Standards: IS 4159, IEC 60335, IS 2825, ASME Sec VIII Div.1
Inspection & Testing:
• Hydrostatic testing of pressure assemblies
• IR testing of insulation resistance
• High-potential (Hi-Pot) testing
• Element resistance verification and meggering
• Factory Acceptance Test (FAT) with client
Documentation: GA drawings, QAPs, ITPs, test reports, IOM manuals
TANK PAD HEATERS – SURFACE HEATING FOR VESSELS & TANKS
Overview
At Integro we design and manufacture customized tank pad heaters for precise temperature
maintenance, freeze protection, and viscosity control in industrial and hazardous environments.
Tank Pad Heaters, also known as surface heaters or vessel heating pads, are specialized heating elements
designed to be externally mounted onto the surface of storage tanks, drums, or pipelines. They provide
indirect heat through conduction, eliminating the need for direct contact with the process fluid.
Working Principle
Tank pad heaters operate via resistive heating, where electric current passes through a heating element
laminated between insulation layers. The generated heat is transferred to the vessel wall through direct
contact, raising the internal fluid temperature via conduction and thermal diffusion.
They are typically used where immersion heating is not possible (due to fluid sensitivity or design
constraints), or where external retrofitting is required.
Technical Specifications
Parameter Specification / Range
Operating Voltage 230V / 415V AC, 1Ph/3Ph
Power Density Customizable in In W/cm
Heater Dimensions Custom-shaped pads or modular panels
Temperature Control Thermostats, RTDs, Thermocouples + PID.
Control & Automation
Integrated surface-mount sensors (RTD or thermocouple) for closed-loop control
Compatible with digital temperature controllers.
Optional zoning for large tanks: multiple heaters with independent control circuits
Thermally insulated with external lagging to minimize heat loss and improve uniformity
Advantages
• Non-invasive: No contact with process fluid
• Retrofittable: Ideal for installed tanks and vessels
• Uniform heating: Eliminates hot spots and stratification
• Scalable: Modular panels for tanks of any size or shape
Engineering & Customization
Integro provides complete system design for tank heating, including:
• Thermal load calculations based on ambient conditions and tank geometry
• Custom heater layout design (cylindrical, rectangular, or irregular tanks)
• FAT, ITP, GA drawings, and installation manuals
Applications
Industry Application Area
Chemicals Viscous liquid storage, freeze protection for acids and solvents
Food & Beverage Edible oil, syrup, glucose tank heating
Water Treatment Sludge tanks, biological reactor heating
Pharmaceuticals Temperature maintenance of process vessels
HOT AIR GENERATOR
IntegroWrap Series – Hot Air Generators
The IntegroWrap Series is designed for industries that need clean, consistent, and energy-efficient hot
air—whether it’s for process heating or room/environmental heating. These rugged systems are built to
deliver reliable thermal performance across a variety of industrial settings, ensuring your operations run
efficiently, comfortably, and safely.
Whether you’re maintaining the right temperature inside a warehouse or supplying hot air to a production
process, IntegroWrap helps you stay in control of your heat requirements—while keeping energy costs down.
Powerful. Reliable. Efficient Heating for Industrial & Commercial Use
Built Tough for Industrial Environments
• Strong & Durable: Heavy-duty steel casing with anti-corrosion coating
• Efficient Heating: Fast, energy-saving performance with minimal heat loss
• Clean Air Output: Safe, dust-free, and suitable even for sensitive environments
• Flexible Fuels: Works with Diesel, LDO, Furnace Oil, LPG, PNG, Biogas—or go electric
• Smart Airflow: High-speed blowers for uniform air distribution
Silo Heating by Integro
Integro offers advanced silo heating solutions to prevent material freezing, moisture
condensation, and flow blockages in cold weather. Ideal for silos storing grains,
powders, liquids, or chemicals, these systems use external heating jackets, base
heaters, or heat tracing cables tailored to the application. By maintaining consistent
internal temperatures, Integro ensures smooth material
discharge, protects structural integrity, and minimizes
downtime. Designed for energy efficiency and safety, our
solutions suit both metallic and non-metallic silos and can be
integrated with smart control systems for remote monitoring.
Integro’s silo heating keeps your operations running
reliably in any climate.
Ideal for Both Process & Room Heating
The IntegroWrap Series is engineered for dual-purpose use:
Process Heating
• Supplies hot air to support industrial operations
• Used in drying, curing, baking, pre-heating, and thermal treatment
• Excellent for textiles, food processing, paints & coatings, and packaging lines
Room / Space Heating
• Maintains ambient temperatures in warehouses, manufacturing areas.
• Creates safe, comfortable environments during cold seasons
• Helps protect materials and machinery from low-temperature damage
Why IntegroWrap?
• Dual-use versatility – Ideal for both process and environmental heating
• Custom-built for your application – Designed to match your heat load,
layout, and fuel availability
• Energy-conscious – Delivers more heat with less energy
• Safe, smart, and reliable – With expert support and service from Integro
OUR BOUQUET OF
PRODUCTS INCLUDES
Waste Water Evaporators
Flexible Heating Jackets
Drum Heating Chambers
Circulation Heaters
Immersion Heaters
Air Heaters
Electrical Heat Tracing
Under Floor Heating
Food Dehyderator / Tray Driers
Pest Heat Treatment
Tank Fabrication
INTEGRO PROCESS HEATING SOLUTIONS
Plot No. I-62, Site-C, Surajpur Industrial Area, Greater Noida - 201306 U.P. INDIA
Mobile : +91 7042395754, +91 9811113202
E-mail : care@integros.in | Website : www.integros.in
