Plate preparation
Sheet grade, thickness and geometry are selected for the process and mechanical design.
One plate, infinite possibilities
Pillow Plate Heat Exchangers
Custom laser-welded and pressure-inflated heat-transfer surfaces for tanks, immersion systems, chillers and demanding heat-recovery duties.
Discuss your application
HEXNOVAS WORKSHOPPillow plate manufacturing
01 / 06How pillow plates are made
Two sheets become one efficient flow surface.
Two metal sheets are laser-welded in a calculated pattern. The welded plate pair is then inflated under controlled high pressure, creating pillow-shaped channels that distribute the heating or cooling medium across a broad surface.
The finished surface can operate as a vessel jacket, an immersed plate bank, a falling-film surface or a custom thermal component.
Laser welding
A project-specific spot and perimeter weld pattern defines the future flow channels.
Pressure inflation
Controlled pressure forms the channels and establishes the required pillow depth.
Finishing
Connections, forming, fabrication and inspection complete the application-ready surface.
Why pillow plates
Designed around the equipment—not around a fixed exchanger frame.
High heat-transfer efficiency
Inflated channels promote turbulence and improve thermal performance.
Hygienic and easy to clean
Smooth stainless-steel process surfaces support hygienic design and effective cleaning.
Compact integration
Large heat-transfer areas can be built into tanks, walls and restricted spaces.
Flexible customization
Panel shape, dimensions, dimple depth, connections and weld pattern are project-specific.
Low maintenance
The active plate body is fully welded and contains no gaskets.
Robust construction
Laser-welded plate pairs can be engineered for demanding pressure and temperature conditions.
Plate construction
Single-embossed or double-embossed.
The plate construction is selected according to the required process surface, installation method and pressure design.
01
Single-embossed pillow plate
Two sheets with different thicknesses are welded and inflated so the thicker process side remains flat. This makes the construction well suited to vessel shells, tank bottoms and hygienic product-contact surfaces.
- Flat process-facing surface
- Typical sheet-thickness ratio approximately 1:3
- Suitable for tanks and sanitary process equipment
02
Double-embossed pillow plate
Two sheets of similar thickness expand on both sides during inflation. The resulting symmetrical channel is ideal when a flat external surface is not required.
- Both sides form during inflation
- Suitable for immersion and clamp-on systems
- Ideal for plate banks and heat-recovery assemblies
Engineering range
Materials, thicknesses and design pressure.
Final plate thickness, inflation depth, weld pattern and allowable pressure are confirmed by project-specific thermal and mechanical calculations.
Available materials
- Austenitic stainless steels 304 and 316L
- Duplex stainless steel 2205
- Nickel alloys and Hastelloy
- Titanium
- 254 SMO
- 904L stainless steel
Engineered pressure capability
Designs above 100 bar are possible, subject to operating temperature, material, sheet thickness, weld pattern and code requirements.
Certification and documentation scope, including CE/PED where applicable, is agreed for each order.Single-embossed sheet combinations
| Flat side | Inflated side |
|---|---|
| 2.0 mm | 0.8 mm |
| 2.5 mm | 0.8 mm |
| 3.0 mm | 0.8 / 1.0 mm |
| 4.0-6.0 mm | 0.8 / 1.0 / 1.25 / 1.5 mm |
| 8.0-30 mm | 1.25 / 1.5 / 2.0 / 2.5 mm |
Double-embossed sheet combinations
| First side | Second side |
|---|---|
| 0.8 mm | 0.8 mm |
| 1.0 mm | 1.0 mm |
| 1.25 mm | 1.25 mm |
| 1.5 mm | 1.5 mm |
| 2.0-2.5 mm | 2.0-2.5 mm |
Forms and structures
From flat panels to complete thermal assemblies.
Pillow plates can be rolled, formed, segmented and assembled to follow the equipment geometry.
01
Tank jackets
Formed pillow panels follow cylindrical vessel walls for direct heating or cooling.
02
Plate batteries
Parallel pillow plates provide high surface area for immersion and heat-recovery duties.
03
Pillow plate cylinders
Integrated cylindrical surfaces combine containment geometry with thermal control.
04
Immersion bundles
Modular plate banks are arranged around flow, capacity, cleaning and installation space.
05
Cones and formed surfaces
Custom-formed panels extend heat transfer into hoppers and non-cylindrical vessels.
06
Trays and half pipes
Curved sections support custom thermal surfaces and special fabrication geometries.
Industrial sectors
Flexible thermal surfaces for clean and difficult media.
Pillow plates are especially useful where conventional tubular exchangers are difficult to install, clean or integrate.
- Food and beverage
- Dairy and brewing
- Pharmaceutical and cosmetics
- Chemical processing
- Oil and gas
- Industrial heat recovery
- Renewable energy
- Textile processing
Selection data
Tell us the geometry and the duty.
Provide the equipment dimensions, available surface area, process and utility media, temperatures, pressures, allowable pressure drop, material requirement and cleaning method. HEXNOVAS will define the plate construction, weld pattern, connections and mechanical design.
Custom pillow plate engineering