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!


Bye Bye Bore Seizure

What causes conventional heaters to warp and bind?

In conventional 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:

Trust the Dalton Difference and don’t get stuck with conventional bore seizure.

Big Bore - No Problem2019-08-30

Big Bore – No Problem


The unique bi-lateral expansion of Watt-Flex cartridge heaters

eliminates the need for tight fits and makes them well-suited for

use in oversized bores where conventional cartridge heaters

cannot be used effectively - especially after heaters were drilled



Cartridge heater fit is measured as the difference between the

inside bore diameter (I.D.) and the outside dimension (O.D.) of

the heater. The suggested fit for a Watt-Flex Cartridge Heater is

0.010" greater than the nominal heater diameter.


For example, the ideal bore diameter for a 1/2" diameter Watt-Flex

heater (0.495” nominal) would be (0.502” to 0.505").


At the maximum tolerance dimension of the heater (0.497”) and the

minimum bore diameter (0.502), the heater would have a 0.005" fit,

allowing easy insertion and removal.


Generally, smaller diameter heaters benefit from a tighter fit and fit

can be loosened for larger diameters and as length increases.





Friday Funnies


Things that make you go…hmmm…


Do Lipton employees take coffee breaks?


How do a fool and his money GET together?


Why does Hawaii have interstate highways?


How is it that a building burns up as it burns down?


If a train station is where the train stops, what is a workstation?


Why do they put Braille on the drive through bank machines?


If Barbie is so popular, why do you have to buy her friends?


Why do hot dogs come 10 to a package and hot dog buns only 8?


What was the best thing before sliced bread?


Why do we park in driveways and drive on parkways?


Best Strain Relief Solutions!2019-08-13

Best Strain Relief Solutions

We were talking about a custom “Anti-Flex” terminal solution that we do for one

of our customers and I asked why we do it and what problem does it solve. 

That prompted a discussion of terminal strain relief protection and prolonging

heater life by protecting against premature lead wire failure. 


Most people think headers offer strain relief, but without potting, a header offers

little to no strain relief.  Selecting “Anti-Flex” option increases the size of the wire,

for example moving from a 16g to 14g wire.  The larger diameter wire provides

additional protection from bending forces.  Our AFX terminal option, is a step up

over “Anti-Flex”.  Here we weld a pin into the terminal and attach a longer terminal

that is flared to go over the lead wire insulation allowing us to crimp the lead wire

and place an additional crimp onto the insulation.  The ultimate strain relief is our

clip support system.  This option consists of welding the base to the heater and

crimp the clip on and around the lead wires.  The photos below show each of

these configurations.


Strain Relief Solutions:

  • Fully Potted Headers
  • Anti-Flex
  • AFX terminal
  • Clip Support

Helping customers reduce the total cost of heating is the foundation of our

strategic Dalton Difference and the reason we believe customers keep

coming back to us year after year.




Friday Funnies


For the math whiz…there is a probability they may laugh out loud!


What happens when you put a root beer in a square glass?

It just becomes beer.


What do you get when you divide a bovine circumference by its diameter?

A cow pi.


Why should you never mention the number 288?

It’s two gross.


What do you call a number that can’t keep still?

A roamin’ numeral.


A Farmer counted 196 cows in her field. 

But when she rounded them up, she had 200.


What’s the best way to woo a mathematician?

Use acute angle.


Stop Bore Siezure2019-08-13

Stop Bore Seizure

before it stops you!


A maintenance supervisor spent the better part of the night searching for a solution

for his shut down plastic extruder.  His night time “Google” search was the result of

seized conventional heaters along their extruder barrel. He was rewarded when

he came to Dalton and was delighted to find our split sheath technology

stops bore seizure – his specific problem.


The time stamp on the request registered it was well past 11pm in his local time zone.

“I was not expecting a call”, said the surprised Maintenance supervisor who answered

my call.  “That’s part of the Dalton Difference – we are unconventional in a good way,

it’s part of DNA to go the extra mile for our customers.” I replied.


We then went on to have a fruitful conversation on how and why our heaters won’t

Seize. We also discussed ways to connect the heaters – making it easier and

faster to disconnect, remove and replace heaters in the future.


Hubble connectors easy on/off solution...


Stop the cycle of Bore Seizure and downtime at your customers by introducing Dalton’s

Watt-Flex® heaters and you too will be rewarded with a lifetime of loyalty.

Jesse Fox comes aboard2019-08-13

Jesse Fox comes aboard

Jesse Fox, Dalton’s new Regional Sales Manager for the Southeast and Western US and Canada and will begin this Monday August 5, 2019. Prior to starting with Dalton, Jesse served six years in the Marines where he excelled in the deployment of various radar jamming technology.

He leveraged that knowledge into a career at KHRONE and later at Hawk, where he sold and serviced measurement systems used in the petroleum, chemical, water treatment and pulp & paper. Jesse is a quick learner and will apply his hands-on style to help customers with specifying the best heating system for the application.

Jesse and his wife and two daughters live in Massachusetts North Shore where they enjoy the outdoors and helping out in their community. There is no doubt that Jesse will bring this same dedication to service and learning to his new Dalton community too.

Jesse’s contact information is below for your convenience,

Email: This email address is being protected from spambots. You need JavaScript enabled to view it.

Phone: 978-356-9844

Cell: 978-290-0894

Please join me in welcoming Jesse to Dalton Sales Team - Hurrahh!



Closely sealed, fastened, or fitted so that no water enters or passes through.

"a watertight seal" – according to Google.


That’s exactly what we now have with our new extended header/convolute

assembly.  This option seals out water from the platen/tooling back to the

junction box.  We do this through a combination of welding and brazing all

three assemblies to form a watertight seal and is depicted in the photo below.

(keen observers will note the parts are fitted together and neither welded

or brazed)


This new configuration opens new opportunities for Dalton in extreme water/oil

environments like those found in baking, packaging and pulping operations.  Finding

new ways to help customers solve heating problems and run longer is what

the Dalton Difference is all about!


Friday Funnies


Why did the Chicken cross the road?

Karl Marx: It was a historical inevitability.

Timothy Leary: Because that's the only kind of trip the Establishment would let it take.

Nietzsche: Because if you gaze too long across the Road, the Road gazes also across you.

Howard Cosell: It may very well have been one of the most astonishing events to grace the

annals of history. An historic, unprecedented avian biped with the temerity to attempt such

an herculean achievement formerly relegated to homo sapien pedestrians is truly a remarkable


Jack Nicholson: 'Cause it (censored) wanted to. That's the (censored) reason.

Mark Twain: The news of its crossing has been greatly exaggerated.

Signed, Sealed, Delivered2019-07-26

“Signed Sealed Delivered…”


Nothing is more frustrating than seeing your hard-earned profits go down the drain. 

Bad things can happen when water and other contaminants infiltrate heaters. 

Even the best heaters will fail if not protected.  Worse, the impact often takes time

to manifest – there is not always a direct cause and effect – adding precious time to

the final solution.  Fear not – for we have the options and solutions.


Packaging applications are often exposed to chemical or water wash downs and

food processing normally has an added element of release agent/oil in the process

to contend with.  These types of applications are difficult but not impossible for us. 


We have innovative ways to combat contamination – water, oil and debris!


Option 1:  Cost-effective solution that specifies a full weld around header,

RTV potting with MW transition and FX wire, (see photo 1).

Photo 1


Option 2:  A more intensive that incorporates a “sealed collar” with full weld around

header, RTV potting with Teflon or FX wire, (see photo 2). 

Photo 2


Option 3:  For ultimate containment and protection from water to caustic and even

high-pressure wash downs, we offer our BX-5 convolute solution.  Specify

BX-5 convolute and fully potted header to form a completely sealed unit, (see photo 3).



Friday Funnies



On his way to Saturday evening Mass, a priest is stopped by a state trooper for speeding.

The trooper smells alcohol on his breath and sees an empty wine bottle on the floor.


The trooper asks, “Father, have you been drinking?” And the priest says, “Just water.”


The trooper says, “Then why do I smell wine?” And the priest looks down at the bottle and says,


“Good Lord, He’s done it again!”


Stars & Stripes Need You!2019-07-05

Stars & Stripes Need You!


This Sunday, in a steamy stadium in Lyon France, the US Women’s national team,

aka Stars and Stripes, will be taking on Netherlands to decide the 2019 World Cup

title.  Ever since the New England Patriots began their dynasty in 2001, it has

warped the way fans view the NFL. Every action is, in some way, an effort to best

the Patriots. The same has been true with US women’s soccer.  The USWNT is the

best team in the history of the sport – period.  They are expected to win every

tournament they enter: Anything less than a trophy is a failure.


After breaking the tournament’s scoring record in a 13-0 drubbing of Thailand, and

sailing to the top of the group stage, TEAM USA had to claw their way past top

contender and host France, then narrowly escaped with a victory over England to

earn a spot in the finals.


Are the Americans’ grip on the sport loosening? The Orange squad’s talented young

legs are a big advantage in the sweltering heat of this year’s World Cup.   No doubt,

the gap between the U.S. and its competition is closing. It’s not that the United States

is less talented than in years past—they’re still the most skilled in the game—but that

the rest of the world is catching up.


Tune in this Sunday at 6:00 PM GMT / 11:00am EST to cheer them on!



Friday Funnies


Q:        Where will the US Women’s World Cup soccer team go to dance?

A:        The Futball


Q:        How will women’s team USA cool off in Lyon France this Sunday?

A:        Stand in front of the fans


Q:        Where do women’s US World Cup soccer team shop for uniforms?

A:        New Jersey


Q:        What runs around World Cup Soccer fields but never moves?

A:        The fence


Q:        Which women’s World Cup player has the biggest cleats?

A:        The player with the biggest feet


Teach'em to Fish2019-07-05

“Give a man a fish and you feed him for a day, teach a man to fish and you

feed him for a lifetime.” The ancient Chinese proverb perfectly describes this

week’s TGID.


A newly converted customer was using a short high watt density heater and

wanted to go from 100C to 200C.  The customer asked, “What temperature

will the heater get to?”  My reply, “1500 – 1650F”.  “Impossible.” the customer

stated, “my thermocouple readings don’t go above 100C”. 


Convinced our heater was deficient, the customer was adamant something was

wrong the heaters. My attempt to seek additional details about the application

and tooling was thwarted due to its proprietary design. The impasse was finally

broken after sending the Engineering Data page below. 


This new customer was new to cartridge heaters and unfamiliar with how they

worked.  Walking them through the heat study calculation and determining the

required power, they saw for themselves that more heaters were needed.

We at the School of Dalton proudly graduate another student.

Doug Doane retires2019-06-21

We will miss you Doug!

Everyone remembers what it was like in early 2009, so I won’t dredge

up the imagery.  It was our unwavering faith in US manufacturing that

Dalton hired Doug Doane on June 1, 2009.  It is in this back drop, that

Doug began his career at Dalton Electric.  Doug has proven to be an

excellent sales professional, with a nuclear reactor supply of energy

and desire to help his customers, distributors and fellow Dalton

co-workers to remove any obstacle in his path to solve problems.  

He is mighty, fearless, and tireless in his support and advocacy of his

customers and channel partners.  Doug has aggressively pushed the

organization to achieve and perform the formerly unachievable.  In his

10 years at Dalton, Doug has been single minded in his pursuit of new

customers, new applications and new business in general.  Doug’s

enthusiasm and energy will be sadly missed in the halls of Dalton.


But he is on another mission now.  Since buying his retirement home in

Downeast Maine, Doug and his wife Julie have been on a non-stop

Migration, moving bits and pieces of their home and life “up to Maine”. 

Doug is an avid fisherman and in between caring for the mammoth

draft horses at his brothers rescue farm, he intends to spend more

time casting his line in the pursuit of landing another big fish. 


Doug and Julie have one grown son, Jonathan.  He and his wife Kristen

have 7 year old daughter.  The love and devotion of a grandchild cannot

be understood unless you have one.  Doug and Julie have been deeply

involved in helping shape her young life and are both excited about the

prospects of being able to spend even more time with their family.


Doug, you have left a lasting legacy here that will live on.  Our doors

and hearts will forever remain open to you and your family.  Until then,

we bid you a fond farewell, arrivederci, adieu, adios, auf wiedershen,

goodbye dear friend.


     Friday Funnies

The best time to start thinking about your retirement is before the boss does. —Author Unknown
A retired husband is often a wife’s full-time job. —Ella Harris
A lot of our friends complain about their retirement. We tell ’em to get a life. —Larry Laser
When a man retires and time is no longer a matter of urgent importance, his colleagues present him with a watch. —R.C. Sheriff
Retirement: That’s when you return from work one day and say, “Hi, Honey, I’m home—forever. —Gene Perret
My retirement plan is to get thrown into a minimum-security prison in Hawaii. —Julius Sharpe
He who laughs last at the boss’s jokes probably isn’t far from retirement. —Author Unknown
My parents didn't want to move to Florida, but they turned sixty and that's the law. —Jerry Seinfeld
I enjoy waking up and not having to go to work. So, I do it three or four times a day. —Gene Perret


St. Louis Wins the Stanley Cup!2019-06-12

Singing The Blues

This weeks’ TGID is dedicated to the St. Louis Blues and our friends at

TEMTRON INC, “Process Heat and Control since 1976”. 


It’s been a long time coming for sports fans in St. Louis – especially when it comes

to championship games against Boston franchises.   Boston is the only city to have

had teams that beat every ‘big four’ St. Louis sports teams - The St. Louis Hawks

lost to the Boston Celtics in the NBA Finals in 1961, the Blues lost to the Bruins in

1970, the St. Louis Rams lost to the New England Patriots in 2002 and the Cardinals

lost to the Red Sox in 2013.


May 10, 1970, Bobby Orr slipped the puck into the Blues goal, capturing the victory,

the “cup” and hearts of Bruin fandom ‘fah-evah”.  It also marked the last time the

Blues, one of the most revered and feared franchises in the NHL, made the Stanley

Cup finals.


49 years, 1 month, 2 days later, the curse was lifted, the drought over, the St. Louis

Blues gave the mighty Boston Bruins everything they had and a that little bit more to

claim Lord Stanley’s Cup.  A series that featured hard nose and “jaw” play on both

sides. To my friends at TEMTRON and St. Louis Blues fans across the country,

I raise my cup in solemn salute.


A priest, a minister, and a rabbi want to see who’s best at their job.  So they each go

into the woods, find a bear, and attempt to convert it.  Later they get together. 


The priest begins: “When I found the bear, I read to him from the Catechism and

sprinkled him with holy water.  Next week is his First Communion.”


“I found a bear by the stream,” says the minister, “and preached God’s holy word.

The bear was so mesmerized that he let me baptize him.”


They both look down at the rabbi, who is lying on a gurney with wounds from head to

foot. “Looking back,” he says, “maybe I shouldn’t have started with the circumcision.”

Sealing Bar Blues2019-06-12

Sealing Bar Blues


While out making calls, our salesman received a call from a maintenance

worker who was installing a new sealing line at a fresh salad packaging plant

nearby.  When he arrived at the plant, the maintenance worker described

the situation.  They had just begun setting up a new sealing machine. The

new machine had less clearance at the terminal end of the sealing bar and

did not allow enough space for the current heater with its protective header.

“I can’t get your heater to fit and I don’t want to go back to using those other

heaters that were always getting stuck and burning out”, he exclaimed. 


The meeting moved out to the floor where the new sealing machine was

located.  They inspected the new unit, took measurements of the clearance

for both the new and the old lines, as well as photographs and talked through

some options.


Removing the header was the only way to get the heater to fit but the rapid

sealing jaw movement and vibration could cause lead wire problems. Further

discussion ensued and the decision was made to RTV pot the heater and

attach a right angle inside clip support.  This configuration secures the lead

wire and protects from vibration and movement as well as wash down.

Moreover, the new design could be used on the old and new design. 


The maintenance worker was thrilled he could still use Dalton heaters and

that one heater could be used in all machines. Watt-Flex® eliminates the

two things folks who do sealing care about most;  bore seizure and uneven heat. 

The fact we Reduce the Total Cost of Heat, is an added bonus! “Trust the

Dalton Difference” to keep you from singing the blues.




Friday Fun Facts


Funny things you might not know about “The Stanley Cup” GO BRUINS!

Lord Stanley was the 1892 Governor General of Canada

The cup on top is the same one from 1899, but the rings below are detachable to allow new teams and players to be etched on…and mistakes are left alone.

1971-72 Bruins name is spelled “Bqstqn Bruins” – likely a disgruntled Montreal etch artist.

It has taken a dip into a pool twice, punted into a canal, and left in a Quebec snow bank

Not your everyday holy relic…two babies have been baptized in the Stanley Cup

Sales Detectives2019-06-12

Sales Detectives


Last week one of our sales people was visiting a large press customer with

their distributor sales partner.  It took several years, many meetings and

countless engineering hours to finally close this customer.  Since changing

to Dalton Watt-Flex® heaters the customer observed longer heater life, higher

press efficiency, and reduction in the cost of heating. Recently, they began to

see unexplained failures and called Dalton to solve the mystery. 


After hanging up with the customer, our Dalton sales representative was on

the phone with our distributor partner.  Within hours he had arranged a flight

and a meeting with the customer.  The two sales detectives reviewed their

records in preparation for the visit.  Upon arriving, the duo asked the production

manager a series of probing questions – has anything changed? (material,

speed, temperature, cycle time, new or repair to insulation, new AC units,

fans, or new operators). “Nothing has changed, overall the heaters are great.”

he said, “but every once and a while, we get a long heater that sticks out

and burns out real fast.”


Recalling every heater had a “B” insertion dimension, and that the press had

a wider bottom press than the top, the two sales detectives carefully inspected

the press - two heaters were sticking out 2 inches.  The pair concluded

the bottom press heaters had been installed in the top press. Next, they set

out to solve how to keep it from happening again.  At the tool crib, they

discovered heaters were stored in bins labelled only with the press name.

Interviews with the maintenance crew revealed replacements heaters were

sometimes out-of-stock and had to make do with what they had on hand while

contributing to the incorrect assumption all heaters were the same.


The tandem held an impromptu meeting with the team, (crib clerk, maintenance

and production manager) highlighting the different heaters, while explaining how

and why they act to improve part quality, throughput and the positive contribution

to their performance bonus’.  The team brainstormed corrective actions and

implemented several great ideas on the spot. The tool crib bins were re-arranged,

added different color bins for the top and bottom presses, identical heaters were

assigned a bin location, and re-order levels adjusted. In addition, they decided

to use photos to map out where each heater goes in the press. Meanwhile, the

clever tool crib clerk worked out an automated email to send to the distributor

whenever a heater was requisitioned. 


Mystery solved – a loyal customer is born. “All in a day’s work”, proclaimed the

humble pair.  We know different, it’s the result of great partners, careful preparation,

probing questions, skilled observations, clarifying assumptions, deductive reasoning

and the sincere DESIRE to help. Sales Detectives solving ways to

Reduce the Total Cost of Heat, is another example to “Trust the Dalton Difference”.




Friday Funnies


A Japanese ship was leaving the port and on its way to open sea. The captain went to

go oil some parts of the ship and took his ring off so it wouldn’t get damaged. He left it

on the table next to his bunk. When he returned, it was missing. He had suspected

three crew members could be guilty and asked them what they had been doing for the

ten minutes that he had been gone.


The cook said, “I was in the kitchen preparing tonight’s dinner.”

The engineer said, “I was working in the engine room making sure everything was running smoothly.”

The seaman said, “I was on the mast correcting the flag because someone had attached it upside down by mistake.”

The captain immediately knew who it was. How?




It was clearly the seaman. It was a Japanese ship and a Japanese flag is white with a

single red dot in the middle. It can’t be hung upside down.


Leadership Personified2019-06-12

LEADERSHIP Personified

This week Doug Doane and I travelled to Toronto Canada to take part in a new

conference ‘AceCONNEX 2019’.  Traditionally, tradeshows have been the only

way to connect users and suppliers together in one area.  AceTronic saw a need

in the market to connect customers and suppliers in a more holistic way.  Over

the last 5 years, this idea began to take shape and last year debuted as

AceCONNEX 2019.  Kim Thiara, President and CEO of AceTronic Industrial

Controls, Inc., took a brave step in launching this years conference. The gamble

paid off as more than 200 customers and suppliers showed up to take part and

launched a new beginning for the trade show of the future. 


Kim leads her company with a guiding principal of being of service, “helping

customers achieve their objectives”.  Her passion to ‘help’ and willingness to lead

spills over into the many associations she actively participates in as well.  Specifically,

Canadian Aboriginal Minority Supplier Council (CAMSC), Women’s Business

Enterprise Network (WBENC), the Women’s Business Enterprise (WBE), the

Canadian Association of Mold Makers (CAMM) and the Canadian Plastics Industry

Association (CPIA).


I cannot begin to fathom the long hours spent thinking, preparing, and effort for

such an endeavor, I can only say thank you.  It is the testament of Kim’s great leadership

that they should prevail in the face of long odds and uncertain times.  We at Dalton

are proud to serve alongside her. 



Friday Funnies

  • A day without sunshine is like, you know, night. -- Steve Martin
  • My fake plants died because I did not pretend to water them. -- Mitch Hedberg
  • Behind every great man is a woman rolling her eyes. -- Jim Carrey
  • Do not take life too seriously. You will never get out of it alive. -- Elbert Hubbard
  • I believe that if life gives you lemons, you should make lemonade ... And try to find somebody whose life has given them vodka, and have a party. -- Ron White
  • Always remember that you are absolutely unique. Just like everyone else. -- Margaret Mead



Article in Thermal Processing2019-06-12

Thermal Processing, April 2019


Over the years Eli forged strong relationships with many people, one in particular

was Dave Gomez of Thermal Design.  Jamie Baker, Dalton’s Marketing

and Sales, reached out to Mr. Gomez this past Fall to relay that Eli was retiring

and to ask for his advertising assistance. Dave agreed to help. Last month Thermal

Processing offered us to be their featured company to profile in April’s edition.

This article relays our commitment to customer service, showcases our product

Offerings, introduces “The Dalton Difference” and highlights the upcoming

100 Year Dalton Anniversary. Thermal Processing has also promoted this

edition/article via their social media as well as a complimentary e-mail blast. 


We owe much to Eli, his legacy and greatest achievement is forming the origins of

the Dalton Difference and fostering it over the years with his consistent example of

care and concern for the people he worked with.

Bore Seizure

Uneven Heat

Cost of Heating