Top Reasons Quartz Heating Tubes Burst in Quartz Tube Heating Systems

 


Quartz tube heating systems are essential in commercial and industrial applications like drying, curing, thermoforming, shrink-wrapping, and powder-coating. Their fast heat-up time and precise temperature control make quartz tube heating elements ideal for demanding operations. However, these tubes can still burst, crack, or fail prematurely, leading to production delays, equipment damage, and costly downtime. Understanding why quartz tube heater elements fail is crucial for ensuring safety, improving maintenance practices, and extending system lifespan. Common quartz tube heating element issues typically arise from mechanical stress, electrical faults, thermal shock, contamination, or improper installation and operating conditions.

Typical Mechanical Pressures Leading to Quartz Tube Failure

Mechanical stress is one of the most overlooked contributors to quartz tube failure in commercial heating systems. While quartz appears rigid and durable, it is still sensitive to certain pressure forces—especially when operating at high temperatures.

1. Vibration from Industrial Equipment

Many commercial facilities use heavy-duty machinery such as conveyors, blowers, and stamping presses near quartz tube infrared heating element setups. Continuous vibrations can cause:

  • Micro-cracks along the quartz tube surface

  • Loosening of mounting brackets

  • Excessive movement of the heating rod inside the tube

  • Stress fractures that worsen over time

Over a period of weeks or months, these structural weaknesses can cause the quartz tube to burst during peak heating cycles.

2. Improper Mounting or Clamping

Quartz tubes must be mounted using heat-resistant, flexible supports that allow for expansion. Over-tightening clamps or using rigid brackets creates pressure points. When the quartz tube expands with heat, these stress points act as fracture zones.

3. Accidental Physical Impact

Common in commercial workshops, accidental impacts from tools, metal trays, or carts can cause hairline cracks. These cracks remain invisible to the naked eye but propagate rapidly when exposed to the intense heat generated by quartz heating rods.

4. Misalignment of Heating Elements

If quartz tube heating elements are forced into a mounting fixture or misaligned during replacement, uneven pressure distribution occurs. This mechanical stress leads to localized heating imbalances and premature tube failure.

Mechanical pressure is preventable but requires strict adherence to installation protocols and equipment spacing guidelines in industrial settings.

Thermal Shock and Rapid Temperature Changes

Quartz tubes are engineered to withstand high temperatures, but rapid fluctuations can exceed their thermal tolerance. Thermal shock is among the top causes of quartz tube heating element issues in production facilities.

Why Thermal Shock Occurs:

1. Sudden Start-Ups and Shutdowns

Powering a quartz tube heater from a cold state to maximum output instantly creates extreme temperature gradients. The outer surface of the quartz heats or cools faster than the inner surface, causing internal stress.

2. Exposure to Cold Air Blasts

If cooling fans, air compressors, or ventilation ducts blow cold air directly onto the tube during operation, sudden contraction can occur.

3. Uneven Heating Zones

If reflectors are dirty, warped, or misaligned, heat builds unevenly across the quartz tube. This imbalance causes alternating hot and cold spots, creating internal strain.

4. Moisture Exposure

Even a tiny amount of liquid or condensation on a hot quartz tube can cause immediate cracking. This is especially common in:

  • Food processing plants

  • High-humidity manufacturing environments

  • Facilities with steam-cleaning routines

To minimize thermal shock, operators should use gradual heating ramps, maintain balanced airflow, and ensure the environment remains dry around quartz tube systems.

Overheating Due to Improper Power Supply or Wattage

Electrical issues are another leading cause of quartz tube heating elements failures in commercial environments. Quartz heating rods and quartz tube infrared heating element systems rely on precise voltage and power control.

1. Incorrect Voltage Supply

If the supply voltage is higher than the rated capacity of the quartz tube heater, the filament inside overheats, expands excessively, and bursts the quartz shell. Overvoltage also accelerates oxidation and filament degradation.

2. Mismatched Wattage During Replacement

A common mistake during maintenance is replacing a quartz tube heating element with a higher-wattage unit “for more heat.” This creates excessively high operational temperatures, causing:

  • Quartz softening

  • Structural deformation

  • Tube discoloration

  • Explosive failure under heat stress

3. Faulty Power Regulator or Relay

If control relays or power regulators malfunction, they may:

  • Lock the heater in a continuous “ON” state

  • Prevent cooling cycles

  • Cause runaway heating

This leads to overheating, warping, and bursting of quartz tubes.

4. Blocked Ventilation or Heat Reflection Systems

Overheating also occurs if reflectors behind the quartz tubes are coated with dust, grease, or residue, trapping heat that would otherwise radiate outward.

Electrical and wattage-related overheating is dangerous because failure often occurs suddenly and violently, especially during high-load operations.

Contamination or Foreign Material on the Quartz Surface

Contamination is one of the most underestimated but highly destructive problems for quartz tube heating elements. Quartz must remain clean and free of surface impurities to operate safely.

Sources of Contamination:

1. Fingerprints and Skin Oils

Touching quartz tubes with bare hands leaves natural oils on the surface. When heated, these oils form hot spots, causing localized stress and eventual cracking.

2. Industrial Dust and Chemical Vapors

In commercial environments—especially manufacturing plants, print shops, and chemical processing units—quartz tubes are often exposed to:

  • Aerosols

  • Metallic dust

  • Solvent vapors

  • Grease residue

These contaminants settle on the tube, absorb heat unevenly, and create temperature differentials that lead to tube fracture.

3. Food or Grease Splatter (Commercial Kitchens)

Quartz tube heaters used in food service or drying applications may collect grease or organic residue, creating heat retention zones that compromise structural integrity.

4. Cleaning Chemicals

Harsh cleaning agents can leave behind corrosive film or react with quartz at high temperatures.

To prevent contamination-driven failures, all cleaning should be done with lint-free towels and alcohol-based cleaners, and technicians should always wear gloves when handling quartz tubes.

Manufacturing Defects and Material Impurities

Even high-quality quartz tube heating elements may occasionally fail due to manufacturing inconsistencies. These issues typically reveal themselves early in the tube’s operational life.

1. Air Bubbles or Micro-Inclusions in Quartz

During the extrusion or molding process, tiny air bubbles can become trapped. When the tube heats up, these spots expand unevenly, creating weak points that eventually burst.

2. Impure Quartz Material

Not all quartz is manufactured to the same grade. Lower-quality quartz may contain:

  • Mineral impurities

  • Metal traces

  • Structural inconsistencies

These disrupt heat uniformity and increase the risk of failure.

3. Filament Winding Defects

If the internal heating rod or coil is not wound symmetrically, heat distribution becomes uneven, causing the quartz tube to expand irregularly.

4. Poor Seal Welding

Weak end-cap seals can allow oxygen to enter, leading to tungsten oxidation and tube discoloration before catastrophic failure.

Manufacturing defects are best identified through quality assurance testing or purchasing from reputable commercial heating element manufacturers.

Incorrect Installation or Alignment Issues

Installation plays a critical role in the lifespan of any quartz tube heater system. Even premium quartz tube infrared heating elements can fail prematurely if installed incorrectly.

Common Installation Errors:

1. Forcing the Tube into a Tight Fixture

Quartz requires a small amount of free space to expand. Forcing it into a tight reflector housing or mounting channel creates mechanical pressure that worsens when heated.

2. Misaligned Reflectors

If reflectors are tilted or bent, heat is directed unevenly. This creates thermal stress buildup and weakens the quartz at specific points.

3. Damaged Sockets or Holders

Worn or corroded sockets cause improper electrical contact, leading to:

  • Arcing

  • Hot spots

  • Localized overheating

Any of these can crack or burst the quartz tube.

4. Using Wrong-Sized Replacement Tubes

A slightly oversized or undersized replacement quartz heating rod disrupts system alignment and increases vibration and heat concentration.

Professional installation and routine inspection help prevent alignment-induced tube failures.

Inadequate Cooling or Airflow in the Heating System

Cooling is essential in quartz tube heating systems, especially in continuous, high-intensity commercial operations. Inadequate airflow causes excessive heat accumulation, which eventually compromises the quartz structure.

1. Blocked Ventilation

Dust, paper scraps, food particles, or debris can obstruct ventilation pathways. This traps heat around the quartz tube, causing:

  • Softening of quartz

  • Hot spots

  • Sudden bursting

2. Malfunctioning Cooling Fans

Cooling fans help maintain safe temperature distribution. If motors fail or fan blades become clogged, system temperature can spike dangerously.

3. Poor System Design

Some commercial systems have reflectors or housings too close to the tubes, reducing airflow. This design flaw increases radiant heat absorption and reduces tube lifespan.

4. Operating in Enclosed or Non-Ventilated Spaces

When used in tightly enclosed systems, quartz tube heaters accumulate radiant heat without adequate dissipation.

Maintaining proper airflow, cleaning fans, and ensuring open ventilation paths are key to preventing heat-related quartz tube failures.


Quartz tube heating elements play a crucial role in commercial heating, drying, and curing applications. However, they can burst or fail when exposed to mechanical pressure, rapid temperature swings, improper power supply, contamination, manufacturing defects, misalignment, or poor cooling. Understanding these root causes allow operators to implement preventive maintenance, ensure proper installation, and maintain optimal operating conditions. With consistent inspection and cleaning, quartz tube heater systems can achieve maximum lifespan and deliver reliable performance. Preventive monitoring is the key to avoiding costly downtime, equipment damage, and unexpected quartz tube heating element issues in commercial environments.

PartsFe, your trusted source for top-quality parts for dishwasher, fryer, and griddle from leading brands—delivers fast to keep your commercial kitchen running smoothly and at the best prices in the market.



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