Manufacture of custom-made electric heating elements – tubular, screw-in, flanged, cartridge and special heaters, 100 % Made in Germany
Helios GmbH
NeuenradeNew on Amplifa
Electric heating since 1914 – custom-made heating elements
HELIOS GmbH is a medium-sized, independent industrial company based in Neuenrade that has been manufacturing custom-made electric heating elements since 1914. The product range includes high-performance tubular heaters Ø 8.4 per DIN 44874, finned tubular heaters, screw-in heaters with and without control, flanged heaters up to DN 500 per DIN EN 1092-1, cartridge heaters, tank heaters as well as special heaters such as immersion bath heaters, large immersion heaters, air heaters and flow-through heaters. An in-house design team engineers the heating elements individually and acts as a development partner in the field of electric heating; production ranges from single pieces from one unit up to large-scale series. Sheath tube materials used range from steel 1.0108 through various stainless steels and Incoloy alloys to titanium, with heating conductors made of NiCr 30 20 or NiCr 80 20, embedded in highly compressed magnesium oxide insulating compound. Manufacturing takes place 100 % at the Neuenrade site; heating elements are used, among other things, in hydraulics, gearbox construction, chemical plant engineering, furnace and heat treatment technology as well as food and compressed air technology.
- Site
- Neuenrade
- Processes
- Manufacture of custom-made electric heating elements (tubular, screw-in, flanged heaters), Tubular heater bending/forming (tubular heater forming), Filling machine and reducing mill for tubular heater production, Screw-in heaters without control, Screw-in heaters with control (thermostat/limiter), Flanged heaters (per DIN EN 1092-1 up to DN 500), Cartridge heaters with and without control, Tank heaters (hydraulic oil, heating oil EL, caustic soda, AdBlue)
- Materials
- Steel, Stainless steel, Stainless steel/Alloy, Special material, Titanium, Heating conductor NiCr 30 20, Heating conductor NiCr 80 20, Magnesium oxide (insulating compound)
- Certificates
- VDE certification (tubular heaters), VDE certification tubular heaters, Piece-by-piece testing DIN 60335-1
- Founded
- 1914
- Employees
- approx. 50
- Industries
- Hydraulics, Gearbox construction, Chemical plant engineering, Furnace construction, Food technology, Heat treatment technology
- 01
Design and engineering (in-house team)
- 02
Tube processing: reducing rolling and filling (filling machine, reducing mill
- 03
Forming: bending (fully automatic bending machine CSM Machinery)
- 04
Assembly of the heating elements
- 05
Piece-by-piece testing and quality assurance
Sheath tube and heating conductor materials
Steel (ST 34-2)
Sheath tube for oil heating and applications up to 400 °C.
Stainless steel AISI 316L
Corrosion-resistant sheath tube for aqueous media.
Stainless steel AISI 321
Sheath tube for temperatures up to 750 °C.
Stainless steel AISI 316Ti
Corrosion-resistant sheath tube for various liquids.
Stainless steel AISI 309
Sheath tube for temperatures up to 850 °C.
ALLOY 800 (Incoloy 800)
Corrosion- and temperature-resistant sheath tube.
ALLOY 825 (Incoloy 825)
Special material with high corrosion resistance, among others for service water heaters.
Titanium (Ti 99.6)
Sheath tube with high corrosion resistance for aggressive media.
Heating conductor NiCr 80 20
Heating conductor wire in the tubular heater, depending on the application.
Heating conductor NiCr 30 20
Alternative heating conductor version depending on the application.
Magnesium oxide
Highly compressed insulating compound with high insulation and thermal conductivity.
Brass nipple
Various thread sizes for screw-in heaters.
Neuenrade site
Neuenrade
DEHeadquarters with administration and production
- Part weight / size
- Tubular heaters 240–270 g/m; lengths up to 7000 mm
- Lot size
- from 1 piece to large-scale series
- Materials
- Steel, stainless steel, Incoloy, titanium, brass
- Fully automatic bending machine CSM Machinery
- Filling machine CSM Machinery
- Reducing mill CSM Machinery
Heating elements
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Manufacture of custom-made electric heating elements (tubular, screw-in, flanged heaters)Assembly | Diameter 8.4 mm +/- 0.1 mm; length +/- 2%; power | 6300 mm (steel, 1.4876, titanium); 7000 | 240 to 270 g/m depending on sheath tube | from one piece – Large-scale series | Steel 1.0108, 1.4404 AISI 316L, 1.4541 AISI 321, 1.4571 AISI 316Ti, 1.4828 AISI 309, 1.4876 ALLOY 800 (Incoloy 800), 2.4858 ALLOY 825 (Incoloy 825), 3.7035 Titanium, NiCr 3020, NiCr 8020, Magnesium oxide (insulating compound), Stainless steel 1.4301 (finning), Brass (nipple), Aluminium (casting) |
| Tubular heater bending/forming (tubular heater forming)Forming | – | – | – | – | Tubular heater materials |
| Filling machine and reducing mill for tubular heater productionForming | – | – | – | – | Tubular heater materials |
| Screw-in heaters without controlAssembly | – | Immersion length up to 3,500 mm | – | – | Steel 1.0108, 1.4404, 1.4541, 1.4571, 1.4828, 1.4876 ALLOY 800, 2.4858 ALLOY 825, 3.7035 Titanium, Brass (nipple) |
| Screw-in heaters with control (thermostat/limiter)Assembly | – | Immersion length up to 3,500 mm | – | – | Steel 1.0108, 1.4404, 1.4541, 1.4571, 1.4828, 1.4876 ALLOY 800, 2.4858 ALLOY 825, 3.7035 Titanium |
| Flanged heaters (per DIN EN 1092-1 up to DN 500)Assembly | – | Immersion length up to 3,500 mm × DN 500 | – | – | Steel 1.0108, 1.4404, 1.4541, 1.4571, 1.4828, 1.4876 ALLOY 800, 2.4858 ALLOY 825, 3.7035 Titanium |
| Cartridge heaters with and without controlAssembly | – | Immersion length up to 3,500 mm | – | – | Steel, Stainless steel |
| Tank heaters (hydraulic oil, heating oil EL, caustic soda, AdBlue)Assembly | – | individual cable length | – | – | Steel, Stainless steel |
| High-performance tubular heaters Ø 8.4 per DIN 44874Assembly | – | up to 850 mm standard | – | – | NiCr 3020, NiCr 8020, Magnesium oxide, Steel, Stainless steel |
| Special heaters (immersion bath heaters, large immersion heaters, Z-shape, space heaters, airAssembly | – | e.g. tube length 1000 mm | – | – | Stainless steel, Steel |
| Finned tubular heaters Ø 28 (Form A finned, Form B unfinned)Assembly | – | Installation lengths approx. 390–1105 mm | – | – | Stainless steel 1.4541, Stainless steel 1.4301 |
| Design/engineering of individual heating elements by the in-house design teamEngineering | – | – | – | – | – |
| Quality control/testing (VDE, piece-by-piece testing per DIN 60335-1)Testing | – | – | – | – | – |
3 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Fully automatic bending machine | CSM Machinery | 1 | – | – | Neuenrade |
| Filling machine | CSM Machinery | 1 | – | – | Neuenrade |
| Reducing mill | CSM Machinery | 1 | – | – | Neuenrade |
Additional services
Reference customers
Quality and testing
Manufacturing is accompanied by continuous quality controls. The high-performance tubular heaters are VDE-tested and certified, undergo piece-by-piece testing per DIN 60335-1 and have a drawing approval (certificate no. 40057393, material 1.4828).
| Evidence | Neuenrade |
|---|---|
| VDE certification tubular heaters | |
| Piece-by-piece testing DIN 60335-1 |
History
- 1914
Foundation of the company; rooted at the Neuenrade site ever since, production 100 % Made in Germany.
- 2022
Copyright year of the catalogue documents.
- 2025/2026
Investments in new machines for tubular heater production: fully automatic bending machine, filling machine and reducing mill from CSM Machinery.
- 2026
Visit of the Neuenrade mayor Volker Klüter; presentation of the new product catalogue.