Cartridge Heaters by Dalton TGID Newsletter

Cartridge Heaters by Dalton TGID Newsletter

Cartridge Heaters by Dalton, TGID (Thank Goodness It's Dalton!) Newsletters

Our short and sweet TGID newsletters are emailed every Friday to Dalton distributors. Sometimes you'll find a write up on a new cartridge heater or platen heater application, and other times you'll find tried-and-true selling tips. We also take the time to occasionally spotlight one of our many fine Dalton employees.

One thing you will always find in TGID is our Friday Funnies—this is sure to give you an end-of-week chuckle or smile. We invite you to read, learn, and enjoy TGID!

Cartridge Heaters - Root Cause2020-01-17

Cartridge Heaters – Root Cause

Trouble shooting – asking 5 why’s gets to the root


How you respond when a customer calls in a panic with a line down or other

tragic production failure can make a big difference. When a call like this comes

in, it sets off an internal alarm and we leap into action, much like a fire fighter. 

But this reaction may sometimes get in the way of understanding and we may

miss the “root cause” in our haste to help.


Late last year we had a customer design a new heater for their tool that was

slated for a new machine.  The new machine needed a shorter “cold end”

heater.  The new shorter “cold end” heater arrived and a few months later,

we got the panic call. RMA was issued, heaters were returned, evaluated,

and analysis performed.  Meanwhile the line was down and lots of nervous

folks were anxious to hear what, why and how fast our fix was going to be. 


Our sales engineer had lots of experience with this heater and repeatedly

asked his purchasing contact 5 “why and how” this happened. Eventually,

the purchasing person stated, “Our guys are doing everything the same

way they always have.”  Our sales person then asked the right question,

“did anyone tell maintenance about the shorter cold end?”  They had not.  


The failure was due to more than an inch of the heated zone out of the tool. 

The old machines had a mark on the machine to get to the right insertion

depth.  They used this same thought process for the new machine which

led to heated section outside the tool and the “root-cause”.  A flange welded

at the correct location provided a positive stop to know for sure that the

heater was inserted to the proper depth.


Trust the Dalton difference to deliver unquestioned performance to you and

your customer(s).



Friday Funnies


Excerpts from the snow shovel diaries


December 9

We woke to a beautiful blanket of crystal white snow covering every inch of the

landscape.  What a fantastic sight!  Can there be a more lovely place in the

whole world?  Moving here was the best idea I've ever had! Shoveled for the first

time in years and felt like a little boy again.  I cleared both our driveway and the

sidewalks. This afternoon the town snow plow came along and covered up the

sidewalks and closed in the driveway, so I got to shovel again. What a perfect life!


December 24

6 inches fell, but the snow was packed so hard by the plow guy, I broke my shovel. 

Thought I was having a heart attack.  If I ever catch that @#$% plow driver, I'll drag

him through the snow by his hair and beat him to with my broken shovel.  I know he

hides around the corner and waits for me to finish shoveling and then comes down

the street at a 50 miles an hour and throws snow all over where I've just been! 

Tonight the wife wanted me to sing Christmas carols with her and open our presents,

but I was too busy watching for the snow plow.



Cartridge Heaters Differ2020-01-16

Cartridge Heaters Differ

Not all heaters are created equal


Switching customers from conventional to Dalton Electric’s Watt-Flex® split

sheath cartridge heaters sometimes means users have to let go of old design

features.  These simple things can be big hurdles if not dealt with.


We recently had a customer grow tired of drilling out seized conventional

heaters and decided to switch to Dalton.  Their prior design used “swaged-in”

solid pin conductors.  Our unique design does not allow us to create the

“swaged-in” look, and we supplied solid pins with ceramic potting. 


Moreover, our solid pins are high quality 80/20 NiCr and have exceptional

rigidity and longevity, but they were not as flexible as what the customer

was used to.  Eventually, we changed the design to short high temperature

lead wire with a special terminal connector crimped and soldered in place. 

This saved them time crimping and soldering the connector and now they

have a heater that lasts longer and doesn’t seize.


A shining example of trusting Dalton to make a difference for you and your

customer. Trust the Dalton difference to deliver unequalled performance.


Friday Funnies


Not exactly funny – but these 5 habits from the pages of Inc.

should provide inspiration to improve in 2020


It’s one of the most powerful forces you can develop.  When you live in

trust and trustworthiness, you build the reputation that will serve you

well in the years to come. 

Innovation and creativity

Start now to increase your commitment to actively in consciously creating

your future instead of waiting for good things to happen.  Shift some of

your energy you put into coping into creating a better reality. 

Constant improvement

Just as you have to prioritize saving for long-term financial goals, you have

to prioritize your personal development and self-improvement if you want

to become the kind of person who can face any challenge.  


Whatever your age now in five years you’ll be…well five years older. 

You can make it five years of getting used to the damaging practice of

sitting at a desk all day or five years of cultivating the energizing and

beneficial out of regular exercise. 

Time stewardship

What could you accomplish with a gift of 900 hours?  Save just 30 minutes


of wasted time a day, and that’s what you’ll have in five years.

Cartridge Heater Lets light it up in 20202020-01-16

Cartridge Heater News

“Lets light it up in 2020”


Following a strong performance for Watt-Flex® cartridge heaters, we are looking

forward to another !!!  Our distributors are understanding the message about

Cost of Heating and selling the concept to their customers with great success. 


We have changed our website so that our videos appear in every screen you go to. 

Now, no matter where you are on our site you are one click away from one of our

short informative videos. Customers always have computers on their desk.  A

great sales technique is to take them to and click on our

Reduce Cost of Heating video.  It is only 1-½  minutes long and is a small

investment of time with big rewards. Clicking on the small box in the lower right

of the YouTube screen will expand it to the full monitor.  They may also be interested

in the Even temperature Profile and Eliminate Bore Seizure videos. 

There is nothing like a video to enhance your presentation.


Shining the way to new business is just one of the ways we will light up sales

in 2020. Trust Dalton to make a difference for you this year.




Friday Funnies


- Just read that 4,153,237 people got married last year … not to cause any trouble

but shouldn't that be an even number?


- Did you know that dolphins are so smart that within a few weeks of captivity, they

can train people to stand on the very edge of the pool and throw them fish?


- Resolution #1, (new German word for 2020)



Cartridge Heater 2019 Review2019-12-26

Cartridge Heater 2019 Review


Exciting things are taking shape here at Dalton and I am proud of the way our

team overcame the hurdles put in our path. 


Our revolutionary design and dedicated employees form the back bone and

foundation of our past, present and future success.  It is our employees that

breathe life into our motto, “Trust the Dalton Difference”.  Our success is

also linked to our tremendous relationships and raw material providers who

help us maintain a level of on-time performance that is second to none. 


However, it is you, our dedicated sales network of loyal partners,

that really make a difference for Dalton.  Together, we are stronger, faster,

better, more reliable than we are alone.  These requisite best in class

practices form Dalton’s enduring intellectual properties that no patent can

reveal or competitor replicate.  We believe you agree.


Our goals for 2020 is to improve our lead generation through investment in our

website design and branching out to new marketing platforms. 

Trust Dalton to make a difference for you this year.




Friday Funnies



Re-Gift It!


“My ex-boyfriend used to call me ‘Larry’ as a joke instead of ‘Perri.’ For the holidays

one year, he gave me a Tiffany’s robin’s-egg blue box. Exciting! Inside, I found a

beautiful, initial necklace…but an ‘L,’ for Larry. I tried wearing it, but it was too hard

to explain why the pricey jewelry had the wrong letter. To this day, I’m still in search

of a best friend whose name starts with an L so I can pass it along.”


Cartridge Heaters, Resistance Explained2019-12-26

Cartridge Heaters, Resistance Explained


Many makers of cartridge heaters, specify wattage tolerance as (+/-) 10%

Since wattage is a function of the square of voltage divided by the resistance,

a change in the voltage will result in a much higher change in wattage.


When Dalton Electric manufactures a Watt-Flex® cartridge heater, the cold

resistance tolerance is roughly (+4.5% / -14%).  This lop-sided resistance

tolerance compensates for the number of factors that we know come into

play as a result of our 40+ years of experience producing split sheath

cartridge heaters.


The first consideration is that the cold resistance is lower than hot resistance.

Resistance and wattage are inversely proportional, so as resistance increases,

wattage decreases.


The chart below shows how resistance and wattage change due to temperature;


Resistance Increase (%)

Wattage Decrease (%)

400F / 200C



800F / 425C



1000F / 540C



The critical issue for designers to consider, is making sure the tooling has enough

wattage to achieve setpoint temperature…the controller will take care of the rest. 

Trust the Dalton Difference!



Cartridge Heaters Watt-Flex® Custom Built to Take the Heat2019-12-26

Watt-Flex® Cartridge Heaters  


Custom design your Watt-Flex® cartridge heater to get unmatched performance

for your customers. 

The required wattage (power) for a metal-heating application is equal to the

sum of watts required for material heat up plus watt loss during heat-up,

plus a 20% safety margin added for contingencies.

Power is the Sum of (S)

  1. Start-up Heat up (watts)
  2. Heat loss (watts)
  3. 20% safety factor


To calculate the heater capacity needed to produce a required level of heat,

find the thermal values in the Physical Properties of Materials Table below

and plug them into the following equations:

Calculation of Required Wattage

To calculate the heater capacity needed to produce a required level of heat,

find the thermal values in the Physical Properties of Materials Table below

and plug them into the following equation:

  • WATTS FOR MATERIAL HEAT-UP = ((Weight) * Specific Heat * Delta T (F)) / (3.412 * Heat up Time (hours))
  • WATTS HEAT LOSS DURING HEAT-UP = (Watt Loss per sq. in. * Area (
  • Total Watts Required = (A + B)*1.2 (20% safety factor for contingencies)
  • **Consult Dalton for any questions


Friday Funnies


Erma Bombeck

Thanksgiving dinners take 18 hours to prepare.

They are consumed in 12 minutes.

Half-times take 12 minutes.

This is not coincidence.


My family told me to stop telling

Thanksgiving jokes

...but I told them I couldn't quit "cold turkey.”


If you call a large turkey a gobbler

what do you call a small one?

A Goblet.


Jimmy Fallon

A new survey found that 80% of men claim they

help cook Thanksgiving dinner.  Which makes

sense, when you hear they consider saying

‘that smells good’ to be helping.



After a long Thanksgiving Day of eating and playing,

my 3-year-old granddaughter asked her mother to

carry her. When I asked if her legs were broken, she

said, “Yes, they’re out of batteries.”

Cartridge Heater News - Anniversary Celebration2019-12-26

Anniversary Celebration


Discovering how to find, hire and keep great employees is worth exploring.

Dalton has cracked the code with its focus on faith, family, and teamwork. 


We have been blessed with excellent employees who have a burning desire

to be the best. This translates into our ability to make the finest cartridge

heater in the industry. 


Today we honor

Tara, Eng. Tech – 30years,

Rick, QC – 20 years,  

Roland, Assembly – 20 years

Columbus went around the world in 1492.

That isn't a lot of strokes when you consider the course.  Lee Trevino


America had often been discovered before Columbus,

but it had always been hushed up.  Oscar Wilde

Cartridge Heater Cyber Stories2019-12-26

Cartridge Heater Cyber Stories

Remember when phones were mounted to the wall or when

computers were the size of a car and fed a steady diet of punch cards?

Now we carry enough computing power in our pocket to literally rule

the world.  A new era of thieves have wormed their way into the fabric

of commerce, intruding our machines with trojans and virus’ intent on

stealing our data, our identity, our savings, or worse our businesses. 


Thievery is an ancient practice.  But today’s cyber criminals are sophisticated

and effective.  They have redirected their menace away from “banks and big

business” and focused on easy prey, small independent companies. Many small

companies lack the layers of cyber security designed to thwart their

malicious attacks. But we can protect ourselves.


We lock our homes, our cars’, we put up cameras and motion detector lighting

in an effort to stop criminals.  We need to think the same way about our networks.


Here are some ideas to keep from being a victim of cyber-attack.


Train your people

Invest in cyber training

Use strong passwords

Institute periodic changes to passwords


Engrain behavior 

Be cautious, suspicious, and to stop when something “seems strange”

speak up when something suspicious comes in.  Spread the word,

announce to co-workers something suspicious is a foot


Preempt Potential Scenarios

Advise your team about financial schemes.  For example, letting your staff know

a request to cut a check outside of the norm, must be done face to face and

never via email. Alert your organization to be wary of requests to change bank

accounts, addresses, or any other payment deviations


Cyber Threat Insurance

Talk to your provider to consider this option.  Insurance instruments are available

to help protect a business in the wake of an attack.


Cyber-crimes are a real and present threat to all of us.  As the saying goes,

an ounce of prevention is worth a pound of cure.  Trust the Dalton Difference!


Friday Funnies

Its not fun and games anymore…



Another perfect example of a hack being completely harmless but highlighting

security issues.  In 2011 British intelligence service MI6 took over a radical

Muslim preachers’ online magazine and replaced an article on how to

manufacture IED’s, with a collection of cupcake recipes.

Their response was explosive.



Working in a nuclear power plant should be a safe and secure place to work.

Until a hacker comes along…In 2010, US and Israeli coders unleased a computer

worm on Iranian nuclear facilities. Although some sensitive information was shared

and distributed, the other element of the hack was out of the ordinary. They decided

to upload AC/DC’s track ‘Thunderstruck’ to the main PA system. At random intervals,

the tune would blast out throughout the building.

Cartridge Heater News - Merry Christmas2019-12-20

Merry Christmas

We are reminded at this time of year as we approach

Christmas and the birth of Christ, that this is a season

of joy and hope.  A hope for new beginnings – and the

joy being with the ones we love and for the loved ones

we remember. 


At this year’s Christmas luncheon, we brought our two

collective families together, the Whitney’s and Dalton

employees to spread blessings of joy and hope to all.


To all our readers, Merry Christmas and Happy New Year!


All I want for Christmas is bike, thought a little boy.  The kid is a real bad seed,

and he knows it. He writes a letter to Jesus. "Dear Jesus, if I get a bike for

Christmas, I'll be good for a whole week." He thinks about it, crosses out what

he wrote, and says, "I can't be good for a whole week, I'll be good for five days."


He crosses that out and writes, "I'll be good for four days." Then he thinks again

and says, "Can't do that." He gets down to one day and says, "I can't even be

good for a day."


Then in frustration, he goes in his mother's room and gets the statue

of the Virgin Mary, wraps it up in a blanket, puts it in a paper bag, throws it in the

closet and says, "Dear Jesus, if I don't get a bike for Christmas, you'll never see

your mother again!”


Cartridge Heater - Eye-Popping Measurements!2019-12-20

Eye-Popping Cartridge Heater

Measurements everyone wants to see!

Dalton Electric’s Watt-Flex® revolutionary split sheath cartridge heaters have

unmatched performance and all the right measurements to attract the eye of

discerning maintenance people. 


Our “pin-up” worthy numbers are (2000HR, 2XL, 0BS)…


2000 hours of minimum service life

2 times longer life on average

0 zero bore seizure


More importantly these numbers translate to fast service, heaters made right,

delivered on time.  Heaters that are responsive (energy sipping and heat tools fast). 

It all adds up to an average of 40% reduction in the total cost of heating.

Military camo training funny…


During a “Survival, Evasion, Resistance and Escape (SERE)” course in the

remote woods of Maine, an Ensign disguised as a tree trunk had made a

sudden move that was spotted by the visiting Admiral.  “You simpleton!” barked

the officer. "Don't you know that by jumping and yelling the way you did. 

You could have endangered the lives of the entire company?"


"Yes sir," the solder answered apologetically. "But, if I may say so, I did stand

still when a flock of pigeons used me for target practice. And I never moved a

muscle when a large dog peed on my lower branches. But when two squirrels

ran up my pants leg and I heard the bigger one says, "Let's eat one now and

save the other until winter' - that did it.”


Thank you for your service2019-11-08

Thank you for your service

Dalton Electric thank all the men and women who we depend on to serve and

protect our country. 

Dependability and reliability are the hallmark of Dalton Electric’s Watt-Flex®

revolutionary split sheath heater too.  We warranty it.

Worry-less knowing your equipment is protected against Bore-Seizure and

trust the Dalton Difference to deliver service that is dependable and reliable.


Friday Funnies


The military has a long, proud tradition of pranking recruits.

Here are some favorites:


• Instructed a private in the mess hall to look for left-handed spatulas


• Sent a recruit to medical-supplies office in search of fallopian tubes


• Had a new guy conduct a “boom test” on a howitzer by yelling “Boom!”

down the tube in order to “calibrate” it


• Ordered a private to bring back a five-gallon can of dehydrated water

(in fact, the sergeant just wanted an empty water can)


And finally a funny story that will keep you in stiches:


During basic training at Fort Leavenworth, our sergeant asked if anyone had “artistic” abilities.

Having been an architectural draftsman in civilian life, I raised my hand. Then the sergeant

announced that everyone would get a three-day pass … except me. I would stay behind and

neatly print each soldier’s name onto his Army-issued underwear.


Trick or Treat2019-11-06

Trick or Treat

It’s no trick, nor magic slight of hand – it’s old good old fashioned, fast, reliable

service and heaters that can be depended to work the same way that puts a

smile on maintenance managers. 

The next time your customers are facing scary downtime, trust the

Dalton Difference to deliver service that is a treat to behold.


Friday Funnies

What started as an age-old European tradition originating with the Celtic festival of Samhain,

when people would wear costumes and light bonfires to scare away spirits and ghosts is now

probably the most celebrated day of the year called Halloween. Enjoy the jokes!

What do you call a dancing ghost? Polka-haunt-us

Which ghost is the best dancer? The Boogie Man!

Friend: What are you gonna be for Halloween? Me: Drunk!

What do you call a cheesy Halloween dance? The muenster mash!

When do ghouls and goblins cook their victims? On Fry Day

What's a monsters favorite desert? I-Scream!

How do you write a book about Halloween? With a ghostwriter.

Puller Plug to the Rescue2019-10-25

Puller Plug to the Rescue


The secret to long heater life is protecting heater lead wires and especially

the lead wire terminal pin connection.  This week while visiting customers in

Canada we came across a customer who recently began making a carbon

fiber thermoset part.  The platen/press design required the heater to be 2

inches shorter than tooling and thus requiring the heater two be inserted into

the tooling.  Once new molds were added, the company needed to move

heaters from one mold to another.


Since the heaters were recessed, the only way to remove the heaters was to

pull them out by the lead wire.  Pulling heaters out by the lead wire can

damage the heater.  Normally, we recommend headers or clip supports to

protect the terminal lead wire connection.  But in this case, the header and

clip support would catch and prevent the heater from being inserted into the tool.


The puller end plug, shown below, proved to be the right solution.  Allowing

them to position the heater in correct location in the die and providing a better

way to extract the heater without pulling the lead wires out of the heater.

Puller End Plug Option – threaded cap allows heater to be pulled out when lead

wires are inaccessible or when the heater needs to be positioned within the tooling.


Making the best split sheath cartridge heater is what we do.

Trust the Dalton Difference is not just a motto, it’s who we are.


Friday Funnies

Funny Story Priest, Doctor, Engineer & Golf

They were stuck behind a really slow group of golfers. The engineer fumed,

“What’s with those guys? We must have been waiting for fifteen minutes!”

The doctor chimed in, “I don’t know, but I’ve never seen such inept golf!”

The priest said, “Here comes the greens-keeper. Let’s have a word with him.”

He said, “Hello George, What’s wrong with that group ahead of us?

They’re rather slow, aren’t they?”  The greens-keeper replied, “Oh, yes.

That’s a group of blind firemen. They lost their sight saving our clubhouse

from a fire last year, so we always let them play for free anytime!.”

The group fell silent for a moment.

The priest said, “That’s so sad. I think I will say a special prayer for them tonight.”

The doctor said, “Good idea. I’m going to contact my ophthalmologist colleague

and see if there’s anything she can do for them.”

The engineer said, “Why can’t they play at night?”


Continuous Coil = Even Heat2019-09-27

Continuous Coil = Even Heat

Unlike conventional heaters, Watt-Flex® continuous coil produces uniform temperature

profile over the length of the heater.  Package sealing, platen presses, other tooling

benefit from Watt-Flex even heat profile. In these applications, even heat translates to

improved sealing performance, higher part uniformity, increased throughput and lower scrap. 

Trust the Dalton Difference to deliver these performance enhancing benefits to your customers.

Friday Funnies

Surgeon Talk...

Five surgeons were talking about the best patients...

First surgeon says, "Accountants are the best to operate on because when you open

them up, everything on the inside is numbered."

Second surgeon says, "Nah - librarians are the best. Everything inside them is in

alphabetical order."

Third surgeon responds, "Try electricians, man! Everything inside them is color coded!"

Fourth surgeon intercedes," I prefer lawyers. They're heartless, spineless, gutless,

and their heads and butts are interchangeable."

To which the fifth surgeon, who has been quietly listening to the conversation, says,

"I like engineers. They always understand when you have a few parts left over at the end."

The Ties That Bind2019-09-27

The Ties That Bind

Over the last month, I have had the pleasure to visit with a few of our great

channel partners, I appreciate the warm welcome and the heartfelt words of

condolences extended to the Dalton and Whitney families. 


Eli would say to me, explaining how to introduce and position our Dalton

Watt-Flex® heater, “It’s about reducing the total cost of heating”.  Nothing more,

nothing less.  What I have also come to know is that Bore-Seizure is the biggest

headache and the biggest driver of higher heating costs.  The patented

split-sheath design of the Watt-Flex® cartridge heater reduces your heater

change-out costs by preventing heater bore seizure.

What causes conventional heaters to warp and bind?

In conventional cylindrical heaters, temperature can vary from one side of the

heater diameter to the other. These differentials are caused by heat deflection

within a close fitting bore, and are the most frequent cause of heater warping

and binding during removal.


How the Watt-Flex Split-Sheath prevents bore seizure:

With the Watt-Flex heaters' unique split-sheath design, each half of the heater

expands and contracts independently.  When energized, the heater expands to

make intimate contact with the bore wall. When de-energized the sheath contracts

for ease of removal:


Dalton Electric's standard warranty covers the removal of Watt-Flex Heaters from bores,

provided that the bore fit is a minimum of 0.005" and there is no bore contamination to

cause seizure. 


Creating and delivering the reasons to Trust in the Dalton Difference – is the cornerstone

of our operating philosophy created and nurtured by Eli.  We proudly honor and uphold

these values and know we need to earn your business and trust every day.


    Friday Funnies

Not necessarily funny but sure to bring a smile...


Natural disasters have a way of making people depend on their neighbors in a

way nothing else does and the results can be incredibly moving—as six-year-old

Jermaine Bell proves. The boy had been saving money with his family for a dream

trip to Disneyworld when their neighborhood was suddenly ordered to evacuate

before Hurricane Dorian hit the South Carolina town. Immediately the first-grader

decided that he’d rather use his hard-earned cash to help his neighbors fleeing

the storm than for a vacation. Jermaine stood alongside a nearby road handing

out hundreds of chips, hot dogs, and bottles of water to evacuees. He even

stopped to pray with neighbors who were scared or worried. “I wanted them to

have some food to eat, so they can enjoy the ride to the place that they’re going

to stay." 


Bore Seizure

Uneven Heat

Cost of Heating