TGID Newsletters

TGID Newsletters

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!





The Thank Goodness It’s Dalton Newsletter is entering it’s 16th year of publication, having enjoyed

15 years of Technical articles, sales techniques, items of interest and events at Dalton Electric

Heating and the ever-so-popular Friday Funnies … which is generally read first by most distributor

salespeople.  The presentation of the newsletter has changed little over the years, retaining its

quick-read character with items of interest to the professional reading it.


There have been very few technical errors over the years, but when one is published, there is

always a flurry of emails pointing out the egregious mistake.  I consider it a fortunate occurrence,

as it points out the professionalism of our readership, as well as the fact that the newsletter is

widely read and digested.


As we move into the 16th year, I would encourage any reader to send in a professional success

that you have enjoyed with our Watt-Flex® cartridge heaters, a good sales story to share or a

candidate for our Friday Funnies.  Dalton Electric is running with the highest backlog in our history

right now and it is attributable in large part to distributor success and growth.  We look forward to

the year ahead, working closely with each of you for our mutual success.




           Friday Funnies


A young salesperson peeped into the office of someone who looked like a sales manager,

muttered something, then started walking away. After retreating a little he seemed to change

his mind and headed back to the door -- where after some hesitation, he started to back away



The sales manager, feeling sorry for the young man, and surprised that he was so badly trained,

called him in.  "You're a salesman aren't you? What are you selling?"


"Sir ... uh ... yes ... I'm a salesman. I'm sorry to bother you. I am selling sales novelties, but

I'm sure you don't want any. Sorry to have wasted your time."


Feeling sorry for the young bungler, the sales manager bought two hundred pens with a company

inscription to give the young salesman some confidence and then started teaching him about

selling. He said: "You should have different pre-planned approaches for different kinds of



"But I do, sir,” the young salesman interrupted, “the one I just used is my planned approach

for sales managers. It always works. Thank you!"




What is it that makes an enduring sports figure?  What is it that makes an artist great?  What

is it that makes a company prosper?  There are a number of factors, but one of the most

significant is consistency.  At the present time, Dalton Electric Heating Company is struggling

with the biggest backlog in our history, working daily overtime and Saturdays.


Yesterday I was sitting with one of our Regional Managers when a Quality Technician came to

the door with a Quality Variance Request.  On occasion we will have a heater with some aspect

just out of tolerance and we will contact a customer to see if it is acceptable … a resistance that

is slightly under specification or a heater 1/8” over tolerance.  This request was regarding a

Production mistake that rendered a shorter length of stainless hose.


The Regional Manager quickly and firmly refused to contact the customer (a Distributor) with

the Variance, maintaining that  the short hose was significant and not consistent with our

Quality image.  In full agreement, I simply sat and watched it unfold.  Later, our Production

Manager told me that he was very reluctant to even bother with the Variance Request.  The

heaters were modified with the correct hose length and shipped the same day, but it was not

an extra task that we needed, given our whopping backlog.


Quality consistency, steady sales consistency, cheerful consistent customer response and

consistently exceeding your expectations have caused Dalton to continue to grow and to

serve as the “Go To” supplier of cartridge heaters.  Turn to us for your heaters and we will

reward you with consistent performance.


                        Friday Funnies


Why do we paint Easter eggs? Because it's easier than trying to wallpaper them! 

What do you call ten rabbits marching backwards? A receding hareline. 

What does the Easter Bunny get for making a basket? Two points, just like anyone else. 



Heater Resistance2018-03-23

Heater Resistance


Wattage is often specified as +/-10% across the industry for a cartridge heater.  But wattage

is a function of voltage applied across a resistance wire.  The formula for wattage is voltage

squared divided by the resistance.  So a change in the voltage will result in a substantially

larger change in wattage.  When Dalton Electric manufactures a Watt-Flex® cartridge heater,

the cold resistance wire tolerance is roughly +4.5% / -14%.


These numbers come from 40+ years of experience producing split-sheath cartridge heaters

with a number of factors coming to play.  The first consideration is that the cold resistance is

lower than the hot resistance.  Resistance and Wattage are inversely proportional so, as the

resistance increases, the wattage will decrease.  The factor of resistance change is as follows:


400°F / 200°C   = +3.5%

800°F / 425°C   = +6.9%

1000°F / 540°C = +8.6%


So as the set point temperature increases, the heater will experience a decrease in wattage

proportional to the change in resistance.  Over the life of the heater, chromium will diffuse out

of the NiCr resistance coil and the resistance in the coil will decrease, causing a wattage out-

put increase.  The critical issue in design considerations is that the application has more than

sufficient wattage to achieve the set point temperature during operation … the controller will

take care of the rest.



       Friday Funnies


A child asked his father, "How were people started?" So his father said, "Adam and Eve made

babies, then their babies became adults and made babies, and so on." The child then went

to his mother, asked her the same question and she told him, "We were monkeys then we

evolved to become like we are now."


The child ran back to his father and said, "You lied to me!"


His father replied, "No, your mom was talking about her side of the family."

An Appreciated Complaint2018-03-13

An Appreciated Complaint

We’ve heard the complaint many times before and we are sure to hear it again … but we

never tire of it.  We received an email from a distributor requesting a quote for a heater

that he ordered back in August 1995.  When we told him that we were unable to cross-

reference the part number for an order that far back, he was kind enough to send us our

old invoice.

He did comment that we should find a way to digitize the records from back then.  But

then he proceeded to say that this five heater order was a replacement for the heaters

ordered in 1995 that finally burned out.  He wrote that he has raised four of his five kids

during that time and continued,  “Dalton would have been more help in this endeavor if

your heaters would burn out every once in a while.”

Watt-Flex® cartridge heaters are often more expensive than conventional cartridge

heaters, but they certainly last twice as long (or more), cutting the actual cost of heating

anapplication.  Sure, it means that you won’t sell as many heaters and, for that, we can

offer our sympathy … and some marketing help to expand your customers who will

never stop buying our heaters.



       Friday funnies

A defendant isn’t happy about the way things are going in court, so he decides to give

the judge a hard time.

Judge: “Where do you work?”

Defendant: “Here and there.”

Judge:  “What do you do for a living?”

Defendant: “This and that.”

Judge: “O.K., take him away.”

Defendant “Wait, when will I get out?”

Judge: “Sooner or later.”

Olympic Spirit2018-02-23


Olympic Spirit

Every night these days I get home after work and turn on the T.V. to one or more of the stations

providing Olympic coverage.  And I must admit that I am filled with Olympic spirit.  The games are

a wonderful diversion from the negative politics of the day and the spirited competition between

super athletes is complete with a genuine respect for each other and the joy of Olympic inclusion.

On Wednesday night I watched American Jamie Anderson, Gold winner in the snowboard slopestyle,

give a massive hug to Austrian Anna Gasser when she took the Gold away from Jamie on her last

run in the “Big Air” with a perfect landing and massive point score.  To me, that hug represents the

Olympic spirit depicted by the Olympic interlocking rings, representing five world continents of Africa,

Asia, America, Europe and Oceania.

I am a curler and have enjoyed watching the American men beat Canada and move to successfully

compete with Sweden for the Gold.  And, with the loss of the American women, I am rooting for the

underdog South Korean women.  My understanding of the game and the increased coverage of

matches makes for great entertainment in my home.

And finally, I have enjoyed sharing my wonder at the raw beauty of the mountains of South Korea

with our distributor in Seoul.  We have corresponded nearly every day and it is heartwarming to

share the joy of these games with people a world away.  I will be sad to see it all come to an end

shortly … the only salvation to that loss will be the advent of college basketball and ice hockey

March Madness !!!



      Friday funnies

The Olympic skiing started really well but it was all downhill from there.

Fourth place in the Olympic luge? You win some, you luge some.

I went to the Winter Olympics with 3,000 cans of Tresemme. Turns out Big Hair isn’t one of the events.


Use of the Hot Tip2018-02-16

Use of the Hot Tip


A unique feature of the Watt-Flex® cartridge heater design is its ability to provide a hot tip.

Users of heated marking/imprinting equipment employ the Dalton hot tip design to supply

heat to the end of a bore.  But a hot tip heater can generate substantial heat and, if the watt

density is high and contact is not made with the end of the bore, the coil will open. 



For that reason it is necessary to ensure that the application design allows for intimate

contact between the heated tip and the end of the bore.  To most effectively pull the heat

away from the heated tip, a design should be used to guarantee end-of-bore contact.




The heat sink pictured above has a tapped hole next to the heater hole.  This is used in

conjunction with a flanged heater to push the tip against the end of the bore to ensure

contact and effective conduction heat transfer.  This technique can also be used with the

angled mounting bracket.



Friday Winter Olympic Funnies


What do you call a slow downhill skier?… A slopepoke!


What’s a curler’s favorite kind of food?… Take out!


How is music like figure skating?… If you don’t “C sharp” you’ll “B flat.”

Heater Termination2018-02-09

Heater Termination


The Watt-Flex® cartridge heater has a hollow core pin that extends our of the terminal end

of the heater.  Internally, the resistance coil which produces the heat is wound onto this pin

and welded.  The pin extends ¼” from the end of the heater and the lead wire is crimped

into it.  The wire is flexible at that point and can be brought to a right angle within a short



We are occasionally asked if we can provide  “swaged-in” leads with our heater.  We have

designed an internal wire attachment, but due to our production process, we are limited to

providing a very short lead.  Then we crimp on the desired length of wire and sleeve the

transition.  The wire can be bent immediately out of the heater, but the crimped wire often

represents a compromise to what the customer wants.  Furthermore, it provides a longer

than normal cold terminal end.




With our standard design, the lead wire can be bent over at a right angle within 3/8” from the

terminal end.  The optimum design for limited space outside the bore is simply to shorten

the heater by ¼” to allow the wire to be bent as it exits the bore.  This design optimizes

the heated length in the bore.




     Friday Funnies


One of our interns asked another if she was planning to sign up for our company’s 401(k).


“I’m considering it,” replied the second intern.


Later, the first intern approached me looking concerned.  “I did the math,” she informed me,

“and 401k comes to almost 250 miles.  She’ll never make it” !!!

New England Patriots and Dalton Electric2018-02-02

New England Patriots and Dalton Electric

There are a number of similarities between the Patriots and Dalton Electric …

Product … The Patriots product is entertainment and they are certainly great at it.  They

are arguably the best football team in the world (with apologies to Eagles fans).  Dalton

makes the best cartridge heater in the world.

Integrity … When the Pats make a great play, they don’t beat their chests and bow to

the crowd.  They just go back to the huddle and get ready to make another great play.

Sure, Gronk spikes the ball after a touchdown and Dalton spikes it in a subtle way with

a year end celebratory meal, but then we go back to work on another great year.

Team … all of the Patriot players know what they have to do to contribute to the team’s

success … and they do it.  All of our Dalton employees know what they have to do to

contribute to our company’s success …and they do it.

Go Pats … Go Dalton … Let the party begin !!!  





                         And the winners of the shirt drawing !!!



The Little things2018-01-26

The little Things

We gave a tour of the Production floor to a packaging consultant the other day.  During his

orientation at a number of stations, I found myself talking about the little things that Dalton

Electric production staff do to make the Watt-Flex® cartridge heater optimized for performance.

It begins early in the process with particular attention paid to cleaning the tubes before

assembly.  One critical element to the process is the welding of the resistance wire to the

two pins that will eventually become terminals.  This welding process ensures that we will

not ever develop a high resistance joint at the terminal.





At the other end of the process we crimp Grade “A” Nickel wire into the hollow core terminal pin.

Stranded nickel wire has a coefficient of expansion under heat that almost exactly matches the

stainless steel pin.  In the early days of crimping, a cross section of the crimped pin would

reveal evidence of the stranded wire, creating the possibility of development of a high resistance

joint at the terminal..  But after working with several experts in crimping, a redesign of the crimping

head and nest, pressure and dwell time resulted in a maximized crimp.  A cross section of the

terminal pin now reveals a homogeneous metal surface, devoid of stranding.

As part of our Quality program, the crimping equipment is checked regularly to avoid the effects

of worn tooling.  It’s the little things that we repeatedly do that set the Watt-Flex cartridge heater

apart from the universe of other heaters.



     Friday Funnies

On an icy, bitter cold day I visited my friend.  “I had a rough time getting here,” I told him.  “For

every step forward, I slipped back two.”

“If you slid back two for every step forward, how did you get here?” he asked.

“Well, I allmost didn’t,” I said.  “But then I said to myself, forget it.  And I turned around and

started home.”

Bore Diameter2018-01-19

Bore Diameter

We are often asked what the optimum bore diameter is for a Watt-Flex® cartridge heater.  As we all

know, our split-sheath cartridge heaters expand bilaterally to meet the sides of a bore when energized.

The affects more responsive heat transfer and causes the coil to run cooler to maintain the set-point

temperature, extending the life of the heater. But how much does it expand and what are the optimum

specifications for a bore?


We manufacture the heater .005" under the spec. dimension, with a tolerance of +/- .002". For example,

the ½” diameter heater is produced at .493” to .497”.  We like to maintain a minimum of .005" fit (difference

between the O.D. of the heater and I.D. of the bore) to ensure ease of insertion and removal. In this case,

we take the maximum heater diameter of .497”, add .005’ fit and have a minimum bore diameter of .502”

Allowing for drill tolerance of +/-.002”, the bore should be .502” to .506”.

One of the benefits of our .005” undersized manufactured diameter is that the heater will match the

recommended bore size of conventional heaters.  Smaller heaters with high watt density will often require

a bit tighter hole and larger, longer heaters are much more tolerant of larger and even oversized bores.

A 1/2" diameter (and larger) heater will expand .020" into an oversized, drilled-out bore and operate for

years if the watt density is reasonable. Your best bet if you have any questions is to contact your Regional

Sales Manager or the factory.




        Friday Funnies

Getting away from their high-stress jobs, a couple spends relaxing weekends in their motor home. When

they found their peace and quiet disturbed by well-meaning, but unwelcome, visits from other campers,

they devised a plan to assure themselves some privacy.

Now, when they set up camp, they place this sign on the door of their RV:

“Insurance agent. Ask about our term-life package.”

Three R's for the New Year2018-01-12

Three R’s for the New Year


Reflect … Often times, salespeople will charge off into a new Year without taking time to contemplate

their success and failures over the previous year.  2017 is filled with lessons for anyone who spent the

year selling and asking yourself a few questions will reveal a focus for the coming year.  What did I do

to contribute to successful accounts and what did I do that lead to failure?  With whom did I spend time

that led to real growth and with whom did I spend time where I received no value?  Where did I not

measure up to my potential and what events provided the biggest smiles.


Repent … Now that we have reflected on some of our shortcomings and resulting outcomes that left

us unsatisfied, we can ask ourselves some key questions.  In what areas do I need to improve?

Who are people with whom I was unsuccessful and what could I have done differently to escalate

success?  Who and what are worthy of my dedicated attention in 2018?


Renew … This is the time for design of your annual focus on the path to success ahead.  What are

the commitments that will lead to stronger sales relationships and deeper involvement with the

customers that will impact your territory in the biggest way?  What will be my continuing inspiration

and what success will provide motivation throughout the year?  Taking a bit of time for the Three R’s

will help formulate and provide a plan for the victories of the sales journey ahead.


        Friday Lesson


A popular speaker started off a seminar by holding up a $20 bill. A crowd of 200 had gathered to

hear him speak. He asked, “Who would like this $20 bill?”


200 hands went up.


He said, “I am going to give this $20 to one of you but first, let me do this.” He crumpled the bill up.

He then asked, “Who still wants it?”


All 200 hands were still raised.


“Well,” he replied, “What if I do this?” Then he dropped the bill on the ground and stomped on it with

his shoes.  He picked it up, and showed it to the crowd. The bill was all crumpled and dirty.  “Now who

still wants it?”


All the hands still went up.


“My friends, I have just showed you a very important lesson. No matter what I did to the money, you

still wanted it because it did not decrease in value. It was still worth $20. Many times in our lives, life

crumples us and grinds us into the dirt. We make bad decisions or deal with poor circumstances. We

feel worthless. But no matter what has happened or what will happen, you will never lose your value.

You are special – Don’t ever forget it!

Pack it Right2018-01-05

Pack it Right


I visited an international company in Europe and was greeted with the usual enthusiasm

and warmth extended by so many of our customers.  After the initial greetings and

introductory exchanges, the mood turned a bit cold and I was informed that a shipment

of our heaters was severely damaged in transit. Most of the connection post terminals

had been broken.


So we walked down to their Receiving department and, sure enough, they had a sizeable

collection of damaged heaters laid out on the table.  I asked to look at the box and was

shown to a paperboard shipping box full of styrofoam peanuts.  Well, it turned out that

they were our heaters, shipped to this customer from an OEM customer of Dalton, who

buys in volume and reships smaller quantities.  The shipper had been tough on the box

and the damage was extensive.



Dalton Electric ships all heaters packaged in foam.  Our machine produces bags with

expanding foam which forms a nest around the heaters as it hardens.  This foam has

eliminated all shipping damage and, if at all possible should be used to reship heaters

to customers.  It is another small thing that Dalton does which enhances to quality of

our product arriving at our customers dock.




        Friday Funnies


Just before the final exam in my college math class, a less-than-stellar student

approached me.  “Can you tell me what grade I would need to get on the exam to

pass the course?” he asked.


I gave him the bad news.  “The exam is worth 100 points and you would need 113

points to earn a D.”


“OK,” he said, “and how many points would I need to get a C?”

2018 Advent2017-12-29

2018 Advent

The advent of a New Year is always a time of contemplative reflection for me.  Next week will be filled

with recapping, consolidating data, forecasting and market planning.  But for now, I look back over an

extremely successful year.  In spite of a few downturns, overall company sales and shipments enjoyed

the biggest growth of the decade.  Simply stated … we were blessed.

Those blessings include the daily focus of Dale and Yvette in the office and the addition of Jamie to

our Marketing team, Paul and Tara on the Engineering side and Barb wrapping up the financials.  We

certainly have been blessed with the drive of our three Regional Sales Managers, the technical

proficiency that they bring to the field and their dedication to success at the Dalton office.  And our

newest Manager, Chris, will bring some fresh ideas and focus to the congregation.

Finally, we are blessed with a great team of manufacturing employees, skillfully guided by Steve

and Jim.  They are so quality and production driven that we continue to enjoy success and residual

sales from our growing customer base.  All of these blessings would not be possible without the

continuing dedication of our distributors, and for that, we extend our deepest thanks.

 Happy New Year !!!   




                          Friday Funnies

Take your pick:

My wife still hasn't told me what my New Year's resolutions are. 

My New Year’s resolution is 1080p.

I was going to quit all my bad habits for the new year, but then I remembered that nobody likes a quitter.  

My New Year's resolution is to help all my friends gain ten pounds so I look skinnier. 

My resolution was to read more so I put the subtitles on my T.V.

Merry Christmas2017-12-22

       Merry Christmas


Dalton Electric Heating Co. celebrated another spectacular year with a Christmas Party.  An italian cuisine

delighted one and all, topped with a beautiful Christmas cake and ice cream.  All of the Dalton employees

received a Christmas check, a shiny bulb for their tree with the Dalton logo on it and a professional picture

of the whole crew taken last week.  We all send our greetings for a blessed Christmas holiday, hoping

that your days are filled with loved ones and lots of laughs.  And may we never lose sight of the Reason

for the Season. 








                                     iday Funnies


Can You Name That Christmas Carol  … Clues:



1.   Bleached Yule

2.   Castaneous-colored Seed Vesicated in a Conflagration

3.   Singular Yearning for the Twin Anterior Incisors

4.   Righteous Darkness

5.   Arrival Time 2400 hrs. - Weather Cloudless

6.   Loyal Followers Advance

7.   Far Off in a Feeder

8.   Array the Corridor

9.   Bantam Male Percussionist

10. Monarchial Triad

11. Nocturnal Noiselessness

12. Jehovah Deactivate Blithe Chevaliers

13. Red Suited Man En Route to Borough

14. Frozen Precipitation Commence

15. Proceed and Enlighten on the Pinnacle

16. The Quadruped with the Vermillion Probiscis

17. Query Regarding Identity of Descendant

18. Delight for this Planet

19. Give Attention to the Melodious Celestial Beings

20. The Dozen Festive 24 Hour Intervals 

Contamination Protection II2017-12-15

Contamination Protection II

Last month we discussed contamination protection and the techniques and materials used

to provide a barrier.  RTV (Room Temperature Vulcanizing) rubber, ceramic and/or glass and

epoxy can be installed in the terminal cavity of the heater to seal the it against harmful environ-

mental agents and manufacturing process byproducts.

A further process that can be employed is the fully potted header.  A straight or right angle header

is added to the heater and fully potted with RTV, epoxy or ceramic.  This provides the greatest

stability for the termination of the leads, capturing the wire-heater transition in the potting material,

as well as providing a clean appearance as seen below.



But the split in the heater will still allow viscous/liquid substances to work through the seal at the

end of the heater.  In the case of an absolute seal requirement, we provide a “sealed heater”.  This

is accomplished by swaging a tube over the heater sheath, which seals the split sheath together.  

Then a header is welded to this outer tube, completing the seal at the terminal end.  Again, please

consult your Regional Manager at Dalton for the optimum contamination protection.



      Friday Funnies

Why, Why, Why?  Life’s Mysteries

Why do people keep running over a string a dozen times with their vacuum cleaner, then reach

down, pick it up, examine it, then put it down to give the vacuum one more chance?

Why do we press harder on a remote control when we know the batteries are almost dead?

Why does someone believe you when you say there are four billion stars; but have to check

when you say the paint is still wet?