These systems required metal blocks to reach 660°C (1220°F) while maintaining temperature stability for processes such as heating dies and glue pots. The heaters operated at approximately 760°C (1400°F) to achieve the required block temperature. The manufacturer had been using cartridge heaters from another supplier, but failures occurred every eight to twelve months, disrupting production and creating warranty concerns. When they approached Tempco for a solution, engineering analysis revealed that the existing heater design and installation practices were not optimized for these extreme operating conditions.