ENERGY EFFICIENCY AND INNOVATIONS IN INDUSTRIAL ELECTRIC HEATING ELEMENTS: TECHNOLOGY COMPARISON, CASE STUDIES, AND STRATEGIES FOR PROCESS OPTIMIZATION

Abstract

This article presents an in-depth study on the efficiency, applications, and technological innovations of industrial electric heating elements, focusing on plastic injection molding machines, extruders, and high-performance gastronomic equipment. The research combines a literature review, comparative analysis of technologies (mica, ceramic, infrared, and tubular sheath), real-world case studies from Brazil and the United States, and energy-saving simulations. Key industrial efficiency problems—such as losses through conduction, convection, and radiation—are discussed, and technical solutions for their mitigation are proposed. The study includes thermal power calculations, performance tables, economic projections, payback analysis, and strategic implications for industrial competitiveness. Results indicate that modernizing heating elements can reduce energy consumption by up to 18%, increase component lifespan, and improve product quality, making it an essential strategy for industries seeking sustainability and high operational performance.