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Over the past two years a revolutionary world first has been steadily established at Infrared (IR) heating specialist Ceramicx.

The benefits to Ceramicx customers have been many and varied: The company has targeted investment in pressure casting systems, together with innovative technology in machining, mould tool design and new investment in laboratories and environmental testing. Ceramicx has now successfully traded the craft variability of bench casting for the precision of pressure casting based systems.

Sometimes in manufacturing it takes a sudden opportunity to trigger a quantum leap in quality or quantity. For Ceramicx both issues came at the same time when a leading Tier 1 automotive lighting supplier asked for a new-design volume product – a low voltage IR DC heater to de-ice headlights with LED lighting.

Ceramicx has long taken pains to put its customer at the forefront of all development projects including major advancements in ceramic technical parts, including the use of moulded in dust pressed parts with pressure casted technical parts. These projects typically develop and advance the art and science of IR heat work for well-defined and practical outcomes.

Having successfully completed its baptism of fire on a number of new designs and with these new projects Ceramicx quickly realised that its new pressure casting capabilities could be expanded to handle the bread and butter of the company’s core business in manufacturing IR heating elements, coupled with designing and building engineered combinations of the same.

Five pressure casting machines were accordingly installed over a period of time: moving the bulk of Ceramicx element production from manual bench casting towards automated and semi-automated industrial production.

The new Ceramicx industrial pressure casting production system is today defined by a consistent flow of slip (ceramic material) that is regularly tested and constantly supplied to machine production.

State-of-the-art pressure casting machinery helps to eliminate human error and guarantees consistency in the moulded product.

Optimising air and water systems together with the in-house design and production of precision moulds also gives Ceramicx optimal control over the ceramic-based IR heating elements manufactured by the company.

A highly trained Ceramicx team keeps the pressure casting operation running smoothly. The company can now flex its modus operandi depending on the status of the order book; allowing industrialised ceramic element production.

As a result of in-house investment and increased capacity, replacing resin moulds to accommodate any new order is a very quick task. It is machine installed, reliable and cost effective, allowing Ceramicx to mix and match different elements throughout the working shift when necessary. The factory is built for development and research that is optimised for the specific needs of its customers.

Ceramicx also listened to its customer base when establishing the new product range from the pressure casting systems: For example, there was demand for a stronger and separate ‘pillar’ build from the main IR heating elements – vitrified and mechanically strong, accurate and insulative.

In response, Ceramicx now has a dedicated pressure casting machine specifically for pillar production – and has designed and engineered bespoke workstations for the wiring of those pillars before fitting them to the IR elements in a separate operation.

Each pressure casting production cell now includes:

•  A pressure caster operative – who is responsible for controlling the machine and its output, also with maintaining the flow and the placements of elements.
•  Wiring stations – where operators work with machines specially designed by Ceramicx that not only enhance precision with the placement of coils but can also be adjusted to suit all combinations of wattage and voltage.
• -An assembly area – where a highly trained level of focus and attention to detail is required.

There are numerous benefits to the pressure casting revolution at Ceramicx: Unlike bench casting, the semi-automated nature of the process diminishes the possibility of human error considerably.

Instead, the pressure casting machine in combination with the precision moulds, performs all the work, ensuring uniformity in every piece and providing a solid foundation for IR heating elements made to tight tolerances. If a larger quantity of elements is suddenly needed at a faster rate, the new facilities – when combined with the skilled operators – provide the flexibility to achieve industrial production with minimal disruption.

At the time of writing the vast majority of Ceramicx products are now manufactured using the pressure casting process. These elements include: FTE, HTE, FFEH, HFEH, QFEH, SFEH, SFSE-LN and the recently developed ESE bulb range.

The net result of all such core production changes – accounting for an investment of some 2.4 million Euros in the past four years – has been to elevate Ceramicx above the competition. The reliability of supply, design, consistency of part and increased productivity has all helped to stabilise the supply side – while also producing a technically advanced, quality product at an extremely competitive price.

Ceramicx can now make IR heating products bespoke for designers and customers at the start of any project: discuss shapes and ideas for parts and elements; get the tools designed, prototyped and built in-house, get the products checked, environmentally tested and into full production in a matter of weeks – all under the Ceramicx roof at a very effective cost.

The Ceramicx design process begins with the assistance of Advanced CAD Software such as Solidworks in addition to other mechanical and electrical design tools used by the Ceramicx team. Once the initial design is ready, Ceramicx creates a 3D-printed prototype via additive manufacturing. This prototype is reviewed by the company’s quality and production teams, and if necessary, with the customer, in order to ensure it meets all requirements and expectations.

After finalizing the design, Ceramicx proceeds with creating all further technology, working from the master mould. Ceramicx uses a special engineering polymer to create the master mould to ensure a high-quality surface and excellent stability.

Once the design phase is complete, the focus shifts to the tool room: An expert tool making team – equipped with high-precision DMG Mori machines – then casts the resin-based mould. The Ceramicx tool room operates both morning and evening shifts to ensure the process is error-free and efficient.

When these products first come off the pressure casting line Ceramicx tests their fitness for purpose, thanks to the company’s purpose-built laboratory. This facility – now established for ten years – has a dedicated workforce, houses an automated test machine, an environmental test chamber and many other devices that simulate all conditions in the field.

The environmental test chamber, for example, operates temperatures from -50 to +190 °C with humidity (%) 0 to 100%

The Ceramicx test chamber is typically used for IR heatwork in:

Testing de-icing heaters (for automotive OEMs), simulating drying conditions for different materials and element testing under extreme conditions(e.g. A standing start at -25°C)

Every industrial innovation carries a disruption factor and a cost, and Ceramicx has certainly endured its growing pains in matching the pressure casting vision to its fundamental IR heat work over the past three years.

The results, however, are definitely worth the wait. The benefits of pressure casting processes over traditional craft production have been proven to be crystal clear.

Having made the technology leap, Ceramicx once again leads the way in IR heat work. All Ceramicx customers are set to benefit in every way.

Ceramicx Pressure Casting – The Benefits:

• Improved product quality
• Improved production throughput
• Quick part design, testing and production of custom-made parts
• JIT delivery of stock products – including ISO and UL qualified
• Short lead times for non-standard products
• International service and support
• Customer focus throughout

 

 

Please note will close for our Christmas Holidays at 4.00 pm on Friday 20th of December and re-open at 8.00 am on Thursday 2nd January 2025.

Ceramicx wish our customers and friends around the world a very happy St Patrick’s Day.

St. Patrick’s Day, Friday 17th March is a Public Holiday in Ireland so Ceramicx will be closed.

Although the holiday originally started as a Christian feast day celebrating the life of St. Patrick and the spreading of Christianity to Ireland, today, it is a celebration of Irish Culture.

The shamrock, a three-leaf clover, has been associated with Ireland for centuries. It was called the “seamroy” and was a plant that signaled the beginning of spring. According to legend, St. Patrick used the plant as a visual guide when explaining the Holy Trinity. By the 17th century, the shamrock had become a symbol of emerging Irish nationalism.

Wishing all our customers, suppliers, employees and friends a wonderful Christmas.

Please note will close for our Christmas Holidays at 4.00 pm on Thursday 22nd December and re-open at 8.00 am on Tuesday 3rd January 2023.

 

Ceramicx contract manufacturing

Contract manufacturing (CM) works on the traditional basis of outsourcing and setting up a manufacturing agreement between the customer and the contract manufacturer. With Ceramicx as the CM, the customer can place their order for products of any size or quantity, transferring the entire manufacturing process over to us, freeing up their time and in-house processes.

But CM with Ceramicx goes much deeper than being just another method of outsourcing. As a leader in the infrared industry, Ceramicx has a global reputation in manufacturing cutting edge infrared components and custom-designed infrared products and heating systems for industries and sectors from aerospace and defence to automotive and construction, and more.

And, as an ISO 9001:2015 certified company, our internal processes – from purchasing, design, and R&D to production, fabrication, and delivery – for all heating assemblies reach the highest quality control standards. ISO also makes us accountable at every stage, giving you the assurance we can take your product from concept to completion – and beyond.

Using Ceramicx as your CM of choice for your specialist infrared heat products, you’re immediately opening your business up to a whole world of expertise, knowledge, and sector experience. But you also get resource and production management as well as cost savings on top.

Ceramicx gives you the edge

So what else can Ceramicx offer as your CM? As your manufacturing partner, we work closely with you to achieve everything you need. We always go

beyond the manufacturing process itself, giving you total value and the edge in your sector, including:

• Infrared solutions

Our engineering experience in the sector gives us the advantage when it comes to creating an infrared heating solution to the specific issue or challenge you’re facing.

• Prototypes

Based on discussions and drawings, we provide working prototypes and samples of your product at each stage, ensuring the continuous improvement of your product until approval.

• Product testing

Our automated test lines ensure all custom components go through all the necessary electrical and thermal tests to meet the highest standards of quality and safety.

• Custom tooling

For any product development, our extensive in-house capabilities allow us to design, develop, and manufacture custom tooling and production moulds.

• Production capability

Our dedicated production facilities mean we can get your product from the design stage to your warehouse with the speed and efficiency you need.

Contract manufacturing with Ceramicx

Choosing a CM for your business and product doesn’t need to be a difficult process, but it needs to be right. Working with Ceramicx as your contract manufacturing partner means you’re in safe hands and we can both look forward to a successful and strategic partnership where nothing is left to chance.

For more information on how contract manufacturing with Ceramicx can help your business, contact us today at [email protected].

What is the super-deduction tax break?

At the budget in April, we heard the announcement of a £25bn tax break aimed at encouraging UK business investment. By helping businesses cut their tax bill by up to 25p in every £1 invested in plant and machinery, the scheme helps firms invest in equipment to boost growth after a COVID-19-challenged year. The scheme is split into two parts:

• A 130% super-deduction capital allowance on plant and machinery investment
• A 50% first-year allowance for qualifying special rate assets

It’s hoped the super-deduction corporation tax relief scheme – which is available for business expenses on “qualifying plant and machinery investments” from 1st April 2021 to 31st March 2023 – will not only increase UK business investment over the next two years but will also increase the overall amount of investment as well.

How does the super-deduction work?

As we know, most tax issues can be confusing, but this scheme is relatively straightforward. Your plant and machinery need to be purchased between 1st April 2021 and 31st March 2023 to qualify and a fact sheet from the government gives us an example of how it works:

“A company incurring £1m of qualifying expenditure decides to claim the super-deduction. Spending £1m on qualifying investments will mean the company can deduct £1.3m (130% of the initial investment) in its taxable profits. Deducting £1.3m from taxable profits will save the company up to 19% of that – or £247,000 – on its corporation tax bill.”

What equipment can you claim for?

There are always rules, terms, and conditions that apply for any kind of tax-related scheme and this one’s no different. But the terminology used is far-reaching, and with most physical assets in any business classed as ‘plant and machinery’ for capital allowance purposes, it’s likely your business can take advantage.

Whether you claim the full 130% super-deduction or the 50% allowance for qualifying special rate assets, the key requirement to qualify for the deduction is that all equipment purchased is new and unused. Any expenditure on second-hand equipment won’t be eligible.

Investment in Ceramicx infrared

The introduction of this corporation tax relief scheme will certainly open doors for many businesses, as the new tax year is still in its infancy, it gives you the opportunity to consider your CAPEX business spending for the next two years. By making a solid investment into machinery that might not otherwise have been possible thanks to recent events, you can now maximise your super-deductions.

With the continuing advancement of infrared technology, Ceramicx infrared heat solutions are increasing in popularity across varied manufacturing sectors and differing applications. As the original alternative energy, infrared is not only cost-effective and energy-efficient but will help your business to take steps towards a cleaner, greener, and decarbonised future.

With that in mind, there’s no better time to discover how this pioneering heat source can transform your processes and move your business forward.

Enquire with us today on what equipment you need.

Interchangeable elements

When faced with an enquiry for supplying a specific, custom-made element, our North American distributors, Weco International, paved the way for an in-house engineering process that’s prompted us to create a brand new product range for Ceramicx.

With the Ceramicx team working on the design, we created a variation on our existing pillared infrared quartz elements that

allowed an easier process for their customer to interchange individual or arrays of ceramic elements to quartz elements and vice versa, quickly and easily.

Although in its early stages, the new range works in the same basic way, and now allows all customers to change their infrared system’s quartz and ceramic components as and when they need to.

New Ceramicx quartz elements

Using our pillared infrared quartz element (PFQE) as a starting point, the first of our new products is the Pillared Full Quartz Element – Leads (PFQE-L). As a direct result of working on the component for our American customer, the design has been engineered and refined to create the new PFQE-L element.

Its key feature is the inclusion of a pillar that’s the same height as included on the ceramic element with additional connection leads so it can easily be interchanged with standard ceramic elements. So if a heating system uses standard ceramic Full Flat Element Hollow (FFEH), one or more of them could be taken out and replaced by the new quartz PFQE-L elements.

Giving users greater flexibility, the new elements allow a complete change in infrared wavelengths for a wider range of applications when previously it meant building a whole new machine. Now, a machine retrofit can be completed using just the new elements to upgrade an entire system.

Ceramicx will also be adding to this new product

range over the coming months. We’ll shortly be releasing a Pillared Square Quartz Element – Leads (PSQE-L), which works in the same way and will be an addition to our existing PFQE and PHQE quartz elements.

 

This will be followed by similar products in due course – watch this space. In the meantime, if you’re interested in purchasing a quantity of the new PFQE-L product, please email [email protected] with your enquiry.

The use of infrared technology is continually advancing across many global commercial and industrial sectors. And, as a leading manufacturer of ceramic and quartz heating elements, our continued development means Ceramicx elements have transformed how infrared heat is used in a range of manufacturing applications.

But, with distinct differences between them, there can often be confusion about which element type is best to use for the

best results. So which Ceramicx infrared heating elements are best for your application?

What Ceramicx heating specialists need to know

To help you find the right element type for your requirements and system, the most important information for us to know is:

• The area you need to heat
• The power and type of element you need to use.
• The target material

This article should give you a head start making that choice.

Ceramic infrared heating elements | Hollow, Flat, or Trough?

A consistently popular radiant heat emitter range, industry-standard ceramic infrared elements are the most efficient element where long cycle times are required.

Ceramic Trough Elements – Long-wave trough elements produce a concentrated heat output that disperses over distance. Best suited to applications requiring emitters positioned further from the target material.

Ceramic Hollow Elements – Long-wave hollow elements filled with high-density insulating material, giving a significant reduction in rear heat loss with increased radiant output from the front of the element.

Ceramic Flat Elements – Long-wave flat elements produce higher operating temperatures and uniform heat output. Best suited to applications requiring emitters positioned closer to the target material.

Ceramic element fast facts

• Wattage: up to 1500W
• Temperature: up to 726°C
• Wavelength range: 3-10µm
• Heat-up time: ~10 minutes
• Most popular elements: FTE, FFEH, SFEH

Quartz infrared heating elements | Standard or Pillared?

Quartz infrared elements can be effective where rapid heater response and/or zone-controlled heat is needed.

Quartz Standard Elements – Short to medium-wave standard quartz heater elements consist of iron-chrome aluminium resistance wires inside highly reflective aluminium clad or stainless steel housing. Better suited to applications that involve continuous movement, their metal studs can withstand mechanical shock better than ceramic mounts of the pillared quartz element variation.

Quartz Pillared Elements – Short to medium-wave pillared quartz heater elements feature exactly the same technical and physical specifications but also include a pressed, ceramic pillar for mounting. With a 42 x 15mm punched slot in the reflector (max. thickness 1.5mm) and a supplied spring and clip, quartz pillared elements are designed for easy element replacement. The pillar also houses screw terminals for connection and can easily be interchanged for ceramic elements.

Quartz element fast facts:

• Wattage: up to 1000W
• Temperature: up to 772°C
• Wavelength range: 1.5-8µm
• Heat up time: ~5 minutes
• Most popular elements: FQE, PFQE

Quartz tube infrared heating elements | Halogen or Tungsten?

As a powerful heat emitter range, quartz infrared halogen and tungsten elements are used in fast-moving processes with shorter cycle times that require extremely high temperatures.

Quartz Halogen Elements – Short-wave quartz halogen heating elements use halogen gas to support the tungsten filament in reaching temperatures as high as 2600°C, with a peak wavelength emission of ~1.0µm.

Quartz Tungsten Elements – Medium-wave quartz tungsten heating elements use a porcupine or star type coil filament to reach operating temperatures up to 1500°C, with a peak wavelength emission of ~1.6µm.

Quartz Halogen and Tungsten element fast facts:

• Wattage: up to 2000W
• Temperature: up to 2600°C
• Wavelength range: 1-1.6µm
• Heat up time: instant

Ceramicx heating solutions

Infrared heat technology has the ability to deliver plenty of benefits to the user, whatever the process or application. Regardless of the demands, each ceramic, quartz, quartz halogen, or quartz tungsten infrared emitter provides precision heat where it’s needed, as well as being cost-effective and energy-efficient.

While delivering on cost and efficiency, making the right choice of Ceramicx infrared element will also mean:

• Reduced machinery or process downtime
• Reduced heat loss to machine surroundings
• Consistent process heating for a reduced product reject rate
• Less time and energy wasted replacing elements beyond essential maintenance
• Better results / better quality product

For more information, complete our enquiry form here or email at [email protected]. We’ll be happy to help you find the right heating solution for you and your business.

 

See also – Ceramicx FAQ page.

Upgrades to meet demand

Infrared technology is continually evolving, and as leaders in infrared heating elements and components for industry, it means Ceramicx has to lead by example. At the heart of everything we do is the technology we invest in, and our in-house machinery needs to help us meet the demand.

Our first upgrade has been to our CNC milling machines. While only used occasionally for a low quantity of production output, our current Hurco VM1 3-axis machine proved crucial to a lot of internal projects. But while giving us the ability to create moulds for many of our other machines, including our industrial ceramic hollow production line and dust press machines, it wasn’t satisfying current requirements.

Speed and accuracy

To help maximise production, step forward our brand new DMG MORI CMX 800 V vertical milling centre. As we run our CNC milling machines overnight producing moulds, this latest technology gives us essential improvements in key areas, together with increased productivity and reliability.

A larger table size and load, together with the increased work area allowing for greater X, Y, and Z-axis travel, gives us more stability. We also now have a much-improved cutting performance with an inline spindle speed of 12,000rpm, giving us a 53% increase in power and 45% higher torque. And there’s even greater accuracy of positioning in all axes up to 6 microns.

Another level of product

Overseeing the installation was our IT Project Manager, Alan Draper, who said “We’re upgrading in this area now to bolster our manufacturing as we’re, by our own standards, not at the level we need to be. We have more moulds for Industrial ceramic production, Dust Press and Progression tooling than ever before, so we needed to increase our manufacturing capabilities to meet these demands.”

But while the CMX 800 V is just the beginning of our planned upgrades, what else is in store? “We have a new DMG MORI NLX2000 lathe coming in shortly which is a very new piece of technology for us, we have nothing on a par with it at the moment, as well as a new laser marking machine. We also have a few things in the pipeline that we are not quite ready to talk about yet, but they should all come together to bring another level to our products.”

While the addition of the CMX 800 V is a significant investment, allowing us to effectively double our current output, it also cements our commitment to productivity and performance as set in our recent ISO 9001:2015 quality management certification.