Industrial Hot Oil Heater Replacement: Signs That It’s Time to Upgrade

At American Heating Company, we’re proud to manufacture industrial hot oil heaters that are built to last for decades. Designed with innovation and durability in mind, our industrial thermal fluid heaters are among the longest-lasting on the market – some lasting upwards of 30 years. 

But inevitably, time passes. Nothing lasts forever. Even if you’ve purchased one of our reliable, high-efficiency heaters, eventually the time to consider hot oil heater replacement will come. 

And when that time comes, we want you to be prepared.

Here, we’ll review key signs that indicate it’s time to replace your industrial hot oil heater, and fill you in on what to do when it comes to navigating the heater replacement process.

Signs That It’s Time To Replace Your Industrial Hot Oil Heater

Even heaters designed for long-lasting performance will eventually reach the end of their lifespans. These signs are good indicators that it’s time to initiate the process of upgrading your industrial hot oil heater.

Decreased Efficiency

With aging equipment, you’ll likely begin to see a decrease in operating efficiency. If you see a notable dip after your equipment has been steadily decreasing in terms of efficiency, it’s likely time to start considering replacement.

The good news is that ongoing developments in industrial heating technology means that new equipment is significantly more efficient than equipment that is decades old. You’re likely to upgrade your efficiency when you invest in a new industrial hot oil heater, which can provide you with a sizable return on your investment.

Undiagnosed Issues

If you’re experiencing ongoing, undiagnosable issues with your industrial hot oil heater, it’s likely time to initiate the replacement process. 

While attempting repairs may be tempting, if you’re struggling to determine the issue you could end up spending a lot of money on repair work and part replacement that ultimately prove to be ineffective. It’s worth considering replacement from the on-set of undiagnosed issues so you can utilize your budget and resources as wisely as possible.

It’s also a good idea to start the hot oil heater replacement process BEFORE your equipment fails. While it may seem like a good idea to wait and see if the issues with your existing equipment can be resolved, there are many benefits to replacing your heater before it fails completely or becomes entirely obsolete.

Unexpected Equipment Failures

Planned updates, part replacements, and repairs are an important part of ensuring that your industrial hot oil heater lasts as long as possible. If you’re hoping to extend the useful life of your heater, a proactive maintenance strategy is a must. 

However, if you’re repeatedly experiencing unexpected equipment failures that cause unplanned facility shutdowns, it may be nearing time for a hot oil heater replacement at your plant. While it’s an added expense and it will cause a planned facility outage to have the new piece of equipment installed, having a reliable hot oil heater and avoiding ongoing unplanned outages can be hugely advantageous when it comes to profitability and efficiency.

Safety Issues and Code Violations

If your hot oil heater is posing safety issues in your plant, or if it no longer satisfies the codes and regulations required in your industry, it’s time to look into replacement. An upgrade may be expensive, but it can be a small price to pay if it prevents a devastating accident or injury, or if it puts your facility back in compliance with industry standards and regulations. 

Difficulty with Parts Replacement & System Compatibility

If you’re looking to replace industrial heater parts but you’re having a hard time finding parts that are compatible, it may be a good indication that you’re going to have to replace your heater in the near future. Once systems can no longer be serviced or repaired, there aren’t many options other than to find a replacement.

Similarly, if you’re replacing a piece of equipment that works alongside your industrial hot oil heater but you’re struggling with compatibility, it may be time to upgrade your heater.

Old Age & Outdated Technology

This may be an obvious indicator, but it’s one worth mentioning. If your industrial hot oil heater is decades old, it’s likely a good time to consider upgrading. You’re missing out on general technology improvements to industrial heater burners, panels, controllers and other components that simply weren’t available decades ago when your existing heater was designed and manufactured.

Ultra low NOx burners (9ppm), linkageless burner controls, and upgraded Honeywell controllers and burner management systems (such as the Honeywell Slate, which provides a wide range of communication options to customers PLCs) are just a few of the new features you stand to benefit from if you invest in a new heater. 

Over the past 30 years, controllers, burners and other heater features have come a long way, giving you the ability to improve facility operations by investing in a new heater that’s reliable and up to date.


This is another somewhat obvious sign that an industrial hot oil heater may require replacement, but it’s again worth stating. 

If your industrial heater has sustained damage, depending on the severity of the damage a heater replacement may be in order. Continuing to operate and rely on damaged equipment can pose safety issues and may cause larger problems for your plant in the long run. If you can easily and affordably replace the heater part that was damaged, do so. If the heater has sustained extensive damage or the repair is prohibitively costly, replacing the entire unit may be the better bet.

Is It Time For a Hot Oil Heater Replacement at Your Facility?

If your current hot oil heater meets any of the criteria listed above, it may be time to consider a replacement. And when that time comes, we are here to help you! 

At American Heating Company, our hot oil heating experts are here to guide you through the heating equipment purchase process. From helping you to determine your facility’s needs to designing a heater to your exact specifications and delivering it to your door, we have you covered every step of the way.

Our American-made equipment is designed and manufactured in the USA, and our heaters are built to last for decades. 

Ready to take the first step towards a hot oil heater replacement you can rely on? Give us a call at (715) 748-5888 or contact us online to get the conversation started and learn more about our equipment pricing.  

Still wondering whether replacement or repair is the right choice for your facility’s heating equipment? Find out why hot oil heater replacement is often the favorable option. 

Shopping your options when it comes to a replacement hot oil heater for your facility? Be sure to keep these things in mind as you search for the ideal hot oil heater replacement.