01 · Model
Drawn and calculated first
Your part is redrawn and, where useful, modelled in 3D – developed length, cold zones and surface load fixed first.
Customised production · to your drawing
Built to your drawing, not to our catalogue.
Most elements we ship are engineered to a customer specification. Send a drawing, a sample or only the installation space and the duty – we design, form and test the element on the lines that make our series parts.
Special does not mean improvised. A custom element is calculated, drawn, sampled and approved before it is produced – with the same 100 % electrical test and lot traceability as a series part.
- Sheath Ø 6.0 – 16 mm in stainless steel, Incoloy®, copper or nickel-diffusion coated stainless.
- Straight rods to three-dimensional forms – bent by CNC, in fixtures or by hand on templates.
- Fittings and safety devices built in: flanges, nipples, brackets, thermal fuses, sensors and BALÇIK TORMEC thermostats.
Drawing to part
What is possible
From Ø 6.0 to 16 mm, from 100 W to 6 kW per element.
These ranges span all our product groups today; designs outside them are reviewed per application. Values per product group are on the Specifications page.
| Parameter | Range | Note |
|---|---|---|
| Sheath diameter | 6.0 – 16 mm | Standard 6.5, 8.0, 8.5, 10, 12, 13.5 and 16 mm; finned elements with approx. 24 – 36 mm fin outer diameter (rectangular plate fins on request) |
| Sheath material | AISI 304, 316L, 321; Incoloy® 800 and 825; copper; nickel-diffusion coated stainless | Copper tinned or nickel-plated; titanium on request for water heating; fins in aluminium, galvanised or stainless steel |
| Power | 100 W – 6 kW per element as standard (higher on request) | Multi-element and three-phase assemblies up to 60 kW |
| Rated voltage | 100 – 480 V, single or three phase | Star or delta connection; 12 – 48 V low-voltage defrost variants on request |
| Watt density | 1 – 25 W/cm² on the heated sheath | Set by the medium: defrost 1 – 3, radiant oven 5 – 8, instantaneous water heaters 12 – 25 W/cm² |
| Forms | Straight rods, hairpins, U, W and M serpentines, loops, rings, flat spirals, coils, finned and three-dimensional forms | CNC bending, fixture bending or hand forming on templates |
| Mounting | Welded brackets and frames; round flanges Ø 48 – Ø 180 mm; threaded nipples G ½″ – G 2″ (BSPP, ISO 228-1) or NPT; shaped rubber flanges with clamp bolt | Brazed or welded in our plant; thermostat pocket tubes on request |
| Terminals | 4.8 and 6.3 mm flat tabs, M4 – M6 studs, ceramic terminal sockets, lead wires, cable with plug, terminal boxes IP54 / IP65 | Connector family and orientation to suit your harness |
| Terminal sealing | Silicone or epoxy resin, PTFE bead, ceramic bead with cement, STF seal | Chosen for the temperature and humidity at the terminal end |
| Built-in devices | Thermofuse (single or double thermal fuse), NTC and PT100 sensors, BALÇIK TORMEC stem thermostats, earth tabs | Trip temperature, sensor type and connector stated on the drawing |
| Packaging | Bulk cartons, trays, customer-specific packaging and labels | Part number, lot, quantity and barcode to your specification |
Ranges reflect BALÇIK TORMEC series production as of 2026. The right watt density depends on the medium, flow and allowed sheath temperature; the final value is validated in our laboratory.
Special shapes
Model, template, fixture – the method follows the part.
A special element is drawn and calculated before any tube is cut. Complex forms and small lots are shaped by hand on templates; repeat geometries move to fixtures and CNC bending.
02 · Check
Checked in your assembly
On request the 3D model goes to your designers, who check clearances and mounting points before samples are made.
03 · Hand forming
3D forms on templates
Three-dimensional prototypes and small lots are formed on templates that fix every bend.
04 · Template
Repeatable small lots
The template fixes bend positions and angles, so each piece of a small lot repeats the geometry of the approved sample.
05 · Fixture
Fixtures for repeat bends
Recurring bends and tight radii are formed in fixtures – faster than hand forming and with less variation.
06 · Scale up
Ready for larger volumes
When volumes grow, the geometry moves to fixtures and CNC bending – the approved drawing and the test plan stay the same.
CoilingFillingRollingAnnealingFormingTesting
Special parts, series processesEvery special element passes the same coiling, filling, rolling, annealing, forming and test steps as a series part.
Small series
Small lots, same discipline.
Prototypes, pilot lots and small series run on the machines, materials and test plan of our series production. Batch size changes the price, not the standard.
- 100 % electrical test and lot traceability on every special element.
- Set-up costs in the open: the quotation states price breaks by batch size and annual volume.
- OEM documentation on request: PPAP-style sample approval and a control plan for special parts in series programmes.
How a special project runs
Five steps from your data to the first lot.
For a new development with your engineering team, the six-stage co-design process applies. For a special part to a given drawing, the route is shorter.
Send the data
Drawing, sample or installation space with power, voltage, medium and annual volume.
Technical review
Surface load, material, cold zones and fittings checked; changes proposed where they extend life.
Offer and drawing
Quotation with price breaks and a dimensioned drawing for your approval.
Samples
Typically 2–4 weeks after drawing approval, made on series processes and tested in our laboratory.
Production
Small or large lots to the approved sample and the agreed control plan.
What we need to quote
- Application: appliance, installation space, mounting and electrical connection.
- Medium: what is heated, maximum operating temperature, permissible surface load if known.
- Electrical data: supply voltage, single or three phase, rated power and tolerance.
- Drawing: dimensions and tolerances, cold-zone lengths, terminals and sealing.
- Requirements: standards and marks, packaging, storage conditions.
- Volumes: annual quantity and batch size.
No drawing yet? The configurator turns your requirements into a specification sheet, and the design guide explains each parameter.
A part but no drawing? Send it. We measure it for your drawing – and still ask about the application, because the part shows what was made, not what the appliance needs.
Plan your element
Everything you need to specify the element.
Have a drawing, a sample or just a space envelope?
Send what you have. We confirm feasibility, propose material and form, and quote samples and series.