Kanthal Introduces Flow Heater Generation 3 to Accelerate High-Temperature Industrial Electrification

Upgraded electric process-gas heating technology combines high power density, precise temperature control and modular scalability to help energy-intensive industries reduce reliance on combustion-based heating and improve operational efficiency.

HALLSTAHAMMAR, SWEDEN – November 3, 2026 – Kanthal has introduced the Kanthal Flow Heater Generation 3, the latest development of its electric process-gas heating technology. The upgraded system is designed to support the electrification of demanding high-temperature industrial processes through improved operational flexibility, high power density, precise temperature regulation and long-term equipment performance.

The launch comes as energy-intensive industries accelerate efforts to reduce carbon emissions, improve energy efficiency and transition towards more sustainable production methods. Electrification is increasingly being considered as an alternative to conventional combustion-based heating, particularly in industrial applications where maintaining high temperatures and consistent process conditions is essential.

However, replacing traditional heating systems in high-temperature operations presents several technical challenges. Industrial manufacturers require heating solutions capable of delivering reliable thermal performance, rapid temperature adjustments and consistent process control while meeting demanding operational and safety requirements.

Kanthal’s latest Flow Heater generation addresses these requirements through a patented direct electric heating technology that transfers energy directly to air and process gases as they pass through the heater core. The system eliminates the need for on-site combustion, offering industrial operators an alternative approach to process-gas heating while supporting the transition towards electrified production environments.

According to Kanthal, the Generation 3 design combines a compact installation footprint with enhanced flexibility and scalability, making it suitable for both continuous and cyclic industrial processes.

Simon Lile, President of Business Unit Heating Systems at Kanthal, said: “Electrification is moving into increasingly demanding industrial processes, and customers need solutions that can meet those requirements without compromising performance. The continued development of the Flow Heater supports that shift.”

Advancing Electric Heating for Energy-Intensive Industries

High-temperature heating remains one of the more complex areas of industrial decarbonisation. Industries such as metals production, battery manufacturing and advanced materials processing depend on carefully controlled thermal conditions to maintain product quality, process stability and manufacturing efficiency.

Conventional industrial heating systems frequently rely on natural gas or other fossil fuels to generate the required process temperatures. Although these technologies are established across manufacturing operations, they can contribute to direct carbon emissions and expose industrial facilities to fluctuations in fuel availability and energy costs.

Electric process heating offers an alternative by converting electrical energy into heat without requiring combustion at the point of use. When powered by low-carbon or renewable electricity, electrified heating systems can help industrial operators reduce the emissions associated with their thermal processes.

Kanthal’s Flow Heater technology is designed to facilitate this transition by directly heating process gases through an electrically powered heater core. Rather than relying on a conventional burner to generate heat, the system transfers electrical energy to the passing gas stream, allowing operators to regulate temperatures according to specific process requirements.

This approach supports applications requiring controlled gas temperatures and rapid adjustments to operating conditions. It also removes the need for on-site fuel combustion within the heating process, providing an alternative for industrial facilities seeking to modernise their thermal infrastructure.

Generation 3 Combines High Power Density with Operational Flexibility

One of the key features of the Kanthal Flow Heater Generation 3 is its high power density, which enables substantial heating capacity within a relatively compact installation footprint.

According to the company, the system’s footprint is comparable to that of gas-burner solutions, offering an opportunity for manufacturers to consider electrification without necessarily requiring extensive changes to available installation space.

The technology also incorporates modular, plug-and-play scalability, allowing heating capacity to be configured according to application requirements. This flexibility can support new industrial installations as well as the conversion of existing process-heating operations from combustion-based systems to electric alternatives.

Another important capability is its ability to accommodate both continuous and cyclic processes. Industrial applications often involve changing operating conditions, including variations in temperature requirements, production loads and process cycles. The Flow Heater’s direct electric heating approach enables fast response and precise temperature control, supporting more flexible thermal management.

These characteristics are particularly relevant for industrial operators seeking to integrate electric heating into complex production environments while maintaining process reliability and operational performance.

Improving Efficiency, Safety and Lifecycle Performance

Beyond electrification, the Generation 3 Flow Heater is designed to address broader industrial requirements related to equipment reliability, operational safety and lifecycle costs.

The direct heating approach enables energy to be transferred to the process-gas stream without relying on on-site combustion. This eliminates combustion-related emissions at the point of use and removes the need for a conventional burner-based heating arrangement.

The system’s precise temperature control and fast response capabilities can also help operators manage changing thermal requirements more effectively. Maintaining consistent process conditions is important in high-temperature manufacturing, where temperature variations can influence product characteristics, production efficiency and equipment performance.

Rishiraj Mukherjee, Global Product Manager at Kanthal, said: “Customers across hard-to-abate industries face growing pressure to improve efficiency, reduce emissions and maintain safe operations while keeping costs under control. The latest Flow Heater was developed to meet those requirements without compromising process performance.”

A further feature of the technology is its refurbishable design. Rather than treating the heater as equipment that must be entirely replaced at the end of its initial service life, the system can be refurbished to support extended operation.

This approach is intended to help industrial customers extend equipment lifetimes, reduce material waste and manage total cost of ownership over the longer term. Refurbishability also supports more resource-conscious equipment management by creating opportunities to retain and reuse equipment components.

Applications Across Metals, Battery Manufacturing and Clean-Energy Industries

The Kanthal Flow Heater Generation 3 is designed for use across several industrial sectors where high-temperature process-gas heating is essential.

Its potential applications include:

• Metals production: Supporting high-temperature heating requirements in metal processing and industrial furnace operations, where precise temperature regulation is important for maintaining process consistency.

• Industrial furnaces: Providing an electric alternative to conventional combustion-based heating systems in applications requiring controlled process-gas temperatures.

• Battery manufacturing: Supporting thermal processes associated with battery production, where reliable temperature management and controlled operating conditions are important.

• Clean-energy technologies: Enabling electrified process heating in industrial applications connected to the development and manufacturing of clean-energy technologies.

These applications reflect the growing demand for industrial heating technologies capable of supporting lower-emission manufacturing without compromising production requirements.

The system’s modular configuration and scalability also provide opportunities for manufacturers to incorporate electric heating into existing facilities or consider it during the development of new industrial installations.

Supporting the Transition Towards Electrified Manufacturing

The introduction of Generation 3 reflects Kanthal’s broader commitment to developing industrial heating technologies that support energy transition objectives.

As governments and industries pursue decarbonisation targets, manufacturers are increasingly examining opportunities to replace fossil-fuel-dependent processes with electrified alternatives. However, the transition requires solutions that can deliver the temperatures, reliability and operational flexibility demanded by industrial production.

High-temperature electrification is particularly important for hard-to-abate sectors, where thermal energy accounts for a significant share of industrial energy consumption. Technologies such as electric process-gas heaters can contribute to this transition by providing alternatives to conventional burner-based systems.

The environmental benefits of electrification also depend on the electricity source. When powered by renewable or otherwise low-carbon electricity, electric heating technologies can help reduce the overall carbon footprint of industrial operations.

Kanthal’s Flow Heater development therefore addresses both the technical requirements of industrial heating and the longer-term need for more sustainable manufacturing infrastructure.

Kanthal Strengthens Its Industrial Heating Technology Portfolio

Kanthal is part of the industrial materials and heating technology sector, specialising in electric heating solutions and resistance materials for demanding industrial applications.

Through the development of technologies such as the Flow Heater, the company is expanding the possibilities for electrifying processes that have traditionally depended on combustion-based heating.

The introduction of Generation 3 represents another development in the evolution of electric process-gas heating, combining direct energy transfer, compact equipment design, modular scalability and refurbishability.

As industrial manufacturers continue to evaluate strategies for improving energy efficiency and reducing emissions, advanced electric heating technologies are expected to play an increasingly important role in the modernisation of production facilities.

With its latest Flow Heater generation, Kanthal aims to help industrial customers move towards electrified high-temperature operations while maintaining the performance, flexibility and reliability required by demanding manufacturing environments.

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