Experimental system hydraulic resistance measurements on a scale air heater unit have highlighted the excessive hydraulic resistance of typical industry configurations. Both poor header inlet conditions and large header expansion angles are shown to contribute to system hydraulic resistance magnitudes 20–100% higher than suitable benchmark cases. Typical centrifugal fan system efficiencies well under 80% multiply the system resistance effects resulting in larger fan power penalties. Velocity profile measurements taken upstream and downstream of the test heat exchanger under flow maldistribution conditions provide insight into the flow maldistribution spreading caused by the heat exchanger resistance. The anisotropic resistance of the plate fin-and-tube heat exchanger is shown to result in resistance induced flow dispersion being concentrated in the axis parallel to the plate fins.