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!

Piro Celebrates 20 Years2019-06-12

20th Anniversary Celebration


Piro, our chief roll mill operator and resident machine expert celebrated his 20th anniversary today.

Fortune smiled on him the day he met our owner.  At the time, Piro was working 95 hours at 3 jobs,  

to make ends meet.  Shortly after this chance meeting and with encouragement from

our owner, our Production Manager brought Piro on board at Dalton. 


20 years later, Piro, a man with a strong sense of duty to family, work and community continues to take

charge here and at home.  His two grown children are now university educated and out on their own.

Within the Albanian community, Piro has lent a helping hand in bringing many new employees to Dalton.

At Dalton, Piro quickly learned new operations and took on various rolls in Dalton production. 

When a new roll mill was purchased, it was Piro who stepped up to become lead

operator.  We are incredibly proud of and honored to award this hard working employee on his

20th anniversary.  We are blessed to have Piro on our team.




  Friday Funnies


This week our funnies pay homage to the 83rd Masters Tournament now in full swing…


Bobby Jones - said at Augusta’s opening ceremony.

“We want make bogeys easy if frankly sought, pars readily obtainable by standard good play, and birdies

Except on par 5s – dearly bought.”


Chi Chi Rodriguez

“The first time I played the Master, I was so nervous I drank a bottle of rum before I teed off. 

I shot the happiest 83 of my life.”


Fuzzy Zoeller - in describing approaching tee time for the first hole of the Masters.

“The greatest natural laxative in the world.”


Hord Hardin – Masters Chairman

“We could make the greens so slick we’d have to furnish ice skates on the first tee.”


Gary Player - leading off the tournament this year with Jack Nicklaus

“Every shot is within a fraction of disaster.  That’s what makes it so great.”


Gene Sarazen

“You don’t come to Augusta to find your game.  You come here because you’ve got one.”


Seve Bellesteros – when asked about a 4 putt from 15 feet

“I miss, I miss, I miss, I make.”


Tom Weiskopf

“If I knew what was going through Jack Nicklaus’ head, I would have won this golf tournament.”


Jimmy Demaret – asked to comment on bridges dedicated to Ben Hogan, Byron Nelson and Gene Sarazen

“Hey, I won three times and I never even got an outhouse.”


Fuzzy Zoeller

“I’ve never been to heaven and thinking back on my life I probably won’t get a chance to go.  I guess

winning the Masters is as close as I’m going to get.”


Quick Guide2019-06-12

Quick Guide


I made table below to guide me through the different sizes and heater configurations we

offer and help answer customer questions quickly. I hope this helps you do the same.


“What is the correct bore diameter?”, is a question I get asked most often. The table lists the

minimum bore diameter and eliminates the many variables that influence the bore size,

tolerance and straightness of the hole.


Another feature of this guide provides the cold section length, as measured from the terminal end to

the beginning of the heated section.  Note these dimensions are the minimum cold end length, special

designs can add length to the cold end should your customer need longer cold sections.


For your inventory specialist and inside sales folks, the codes for cold tip, hot tip and distributed wattage

should help make sure your heaters with different designations do not get mixed up in the wrong ‘bin’.


Lastly, our grooved heater information with corresponding thermocouple column simplified

choosing the correct configuration and making sure the right thermocouple was selected.


The chart is attached for easy printing and for your own ‘internal use’. Good selling!



   Friday Funnies



Proof Positive2019-06-12

Proof Positive!


We have always known that Watt-Flex® heaters are more efficient, provide

even heat and don’t seize in the bore.  The question of how much better is

difficult to precisely measure.  An enterprising engineering manager at a

global packaging company understood the distinct advantages of

Watt-Flex® heater technology and took it upon himself to scientifically

verify and validate the Dalton Difference. 


The excerpt below outlines the testing methodology and its precise degree

of performance improvement over conventional cartridge heaters


“Heaters to be tested in two ways:

  • Installed in a seal bar assembly and profiled in our normal test environment
    • The profile resulted in a similar curve as our regular heaters. 

I have found that our test environment has a lot of influence over the

shape of the profile curve.

NOTE: The Dalton heaters were much more consistent between each unit. 

  • At each measurement point the Dalton heaters were 1-7°F different
  • At each measurement point our regular heaters were 9-18°F different


  • Technician installed one heater in a machine that had two seal bars for comparison
    • The seal quality was the same as our regular setup
    • At steady state the heaters are cycled on and off at a percentage of on time
  • The Dalton heaters were able to run at 32% and maintain temperature
  • Our regular heaters ran at 40% to maintain temperature


It was also noted by the technician who performed the heater profile and the technician who

did the in-machine testing, that the Dalton heater was much easier to install and remove which

is a strong selling point."


This data confirms our claim that Watt-Flex® heater technology provides more even heat

across the sealing bar.  Moreover, the test reveal our heater uses 25% less energy to maintain

set temperature.  Take it from the experts - Watt-Flex® heaters are the best choice for sealing



  Friday Funnies


One day, just before Easter, Sally pulled into the grocery parking lot.  Her husband Joe had

picked up a few things and was waiting on a bench out front.


“Hi Honey,” Sally cheerfully said as Joe got into the car.  “How is your day going?”


“I can’t believe it,” Joe said.  “It looks like our bank is in trouble.”


“Really, why?” Sally asked


“It’s closing at the end of the week,” Joe replied.


“That can’t be right,” Sally said.  “It’s a one of the biggest banks in the country!”


“Well its true,” Joe came back.  “I saw the sign in the window”


“What sign?” Sally asked.


“Drive by the bank and you’ll see,” Joe replied.  Sally headed in the direction of the bank.


“Right there,” Joe said as they drove by the bank. 


Excitedly Joe said, “See the sign?  It says, ‘We will be closed for Good …


Friday April 19 2019”


Get the Wet Out2019-06-12

Get the WET out!

This week I have been working with a distributor to overcome a problem at one

of our end-use customers.  During the course of our investigation we uncovered

the problem and other tid-bits that might benefit all Dalton customers. 


As heating experts, you are aware that cartridge heaters pick up moisture.   

The rate of this process depends on the design and environment which could take

place within hours or may take months. MgO loves water and will absorb moisture

readily.  You may have noticed that Dalton Watt-Flex® heaters are heavier than

conventional heaters – that’s because we pack ten times more MgO in our heaters

than conventional ones.


Cartridge heaters absorbing moisture is a known issue in the industry and its

negative impact on heaters must be monitored, and appropriately dealt with to

prevent premature heater failure. Many users implement various and often ingenious

ways to bake out moisture.


At this particular customer, we designed the heater with RTV potting.  The distributor

believed the heater potted with RTV would be free of moisture forever. The fact is,

even with RTV potting, our heater will take on moisture. Not aware of this fact, the

distributor did not take normal drying precautions and did not advise the customer either. 

Full voltage was applied instead of the recommended 50% voltage soft start procedure

and the heater failed soon after energizing.


Now armed with this information, I expect the customer to enjoy the long-life Watt-Flex®

heaters are known for.  Our heaters are different by design.  We are purposely different in

our single-minded pursuit of perfection in split sheath technology. Trust the Dalton Difference.



Friday Funnies


1. Those who get too big for their britches will be exposed in the end

2. When you’ve seen one shopping center you’ve seen a mall

3. If you jump off a Paris bridge, you are in Seine

4. Bakers trade recipes on a knead to know basis

5. Acupuncture: a jab well done

6. A lot of money is tainted: Taint yours, and taint mine


Terminal Options2019-05-13


Terminal Options


Small diameter heaters have small diameter terminal pins into which the lead

wire is crimped.  Generally, this is not a problem because the wattage is not

too high and the amperage is very low.   But if the application requires higher  

amperage-carrying ability or resistance to repeated flexing, larger diameter  

wire must be employed.


When small diameter pins exclude the use of larger gauge wire, the AFX

termination is used.  A tapered pin is used to accommodate the larger O.D.

of the wire and the smaller end is welded onto the terminal pin.


One other benefit of this construction is that the wire is inserted into the termination

with the insulation.  When a wire is crimped into a terminal pin, that crimp becomes

the focus point for any flexing and stress on the wire.  But the AFX termination

includes the insulation and provides support for the wire.  It also displaces the focus

of the stress to a point that includes insulation.


This is an ideal construction if you have a small diameter heater and the need for

higher amperage capacity or protection against finer wire breakage due to flexing

or cycling as in a packaging machine and other sealing operations.



          Friday Funnies

  1. On the other hand, you have different fingers.
  2. 42.7 percent of all statistics are made up on the spot.
  3. Remember, half the people you know are below average.
  4. Depression is merely anger without enthusiasm.
  5. Support bacteria. They're the only culture some people have.
  6. A clear conscience is usually the sign of a bad memory.
  7. OK, so what's the speed of dark?
  8. How much deeper would the ocean be without sponges?
  9. What happens if you get scared half to death, twice?
  10. Why do psychics have to ask you for your name?


**. Light travels faster than sound. That's why some people appear bright until you

     hear them speak.



Life Expectancy2019-05-13

Life Expectancy


How long does a Watt-Flex® cartridge heater last?  This is a common question that does not have

a definitive answer. It depends on a variety of factors including size of the bore, heat sink material,

watt density of the heater, set point temperature, type of controller, amperage (function of voltage),

presence of contamination, shifts per day and a number of other factors.  We state that our heater

will last up to four times longer in the same application as a conventional heater ... but where do we

get that number?


In house tests can be skewed to produce favorable results so we choose to look at real world

applications and measure our success from customer testimonials.  Back from a trip, one of our

Regional Managers reported that he was in a shop looking at a machine being rebuilt. As part of their

PM the customer was replacing the Watt-Flex cartridge heaters and gave him the old units. From

the date code he found the heaters was over 11 years old and had operated almost continuously

with a reasonably high watt density. Further tests on the heaters proved them to be not only electrically

sound but still within the resistance spec.


This customer had tried less expensive conventional heaters but never got more than one year's

service from them.  We are always promoting the issue of price vs. cost ... this was one customer

that understood the concept well. 


               Friday Funnies


A doctor made it his regular habit to stop off at a bar for a hazelnut daiquiri on his way home. The

bartender knew of his habit, and would always have the drink waiting at precisely 5:03 p.m. One

afternoon, as the end of the work day approached, the bartender was dismayed to find that he was

out of hazelnut extract.


Thinking quickly, he threw together a daiquiri made with hickory nuts and set it on the bar. The doctor

came in at his regular time, took one sip of the drink and exclaimed, "This isn't a hazelnut daiquiri"!


"No, I'm sorry," replied the bartender, "it's a Hickory Daiquiri, Doc."


Speed Wins2019-04-05

Speed Wins

In today’s business world, regardless of what industry you’re in,

if you’re not fast, you cannot survive.  Customers expect immediate

response and don’t have time to waste.  At Dalton, responding quickly

is an absolute must.  We know that lead response within hours increases

our chances of winning significantly.  That’s why our response objective

is to address all quotes within an hour.  We know that customers who

don’t hear from you right away will look for alternatives.  Given that the

Watt-Flex® cartridge heaters are different from conventional cartridge

heaters, we have to overcome more to get the sale. Rapid response

becomes synonymous with both innovation and quality and creates a

high expectation in your customer’s mind.


Speed alone will not necessarily get the job done.  To make the right

recommendation, one has to be able to separate critical data from the

non-essential.  Because we focus on our Watt-Flex split sheath design,

we have the experience and knowledge to perform this complicated task

quickly.  The key to a correctly configured fast quote depends on knowing

the few required specifications, which are listed below for easy fast reference. 

Items on the left side are “must have” information and items on the right are

“like-to-have” …

A rapid response will be unnecessarily delayed when these “must have” specifications

are unknown.  Precious time ticks away if you have to go back to the customer with

additional questions.  When it comes to speed, we know we must deliver it every day. 

Dalton has the speed and ability to make the difference and win. 

Trust the Dalton Difference to finish first.





  Friday Fun-osophy


Sometimes you need to unplug your life, wait 60 seconds, and then plug it back in.


Another reason to take the high road…there is less traffic


A good goal should scare you a little and excite you a lot!


If you can see the invisible, you can do the impossible.


You have three choices in life;

  1. Give up,
  2. Give in,
  3. Give it all you’ve got.


Only dead fish go with the flow.


Sometimes the best thing to get off your chest is your chin.


Greatness is measured by your gifts, not your possessions.

Consistent Quality Wins2019-03-15

Consistent Quality Wins


Dalton’s ability to consistently craft custom made to order heaters is

one of the reasons Dalton continues to win at customers. Since I

arrived 16 months ago, I have seen us compete and win against low cost,

low quality heaters despite our higher price per cartridge. 


This week we had two situations where seam sealing customers were

frustrated with low-cost conventional heaters.   One customer had to

scrap many heaters due to lead wire failure during installation and another

was unable to achieve a stable, consistent seam seal.  We won the

business at both customers because of our high quality construction and

due to our unique continuous coil design. 


Of course, Dalton’s Watt-Flex® continuous coil design provides unmatched

even heat in sealing bar applications.  However, it is our production team’s

attention to details that ensures our customers get the highest quality

custom crafted heater that makes the real difference.


It is our dedicated team of assembly and production workers that give

us the edge against competition. They are the unsung heroes.  They

take great pride in the job they do and the company overall.  They are

the ones responsible for our high quality, consistent, reliable,

performance that we have all come to rely on.   


On this St. Patrick’s weekend, I tip my hat in appreciation to the

men and women of Dalton who deliver on our promise of making the

world’s best heater.




  Friday Fun Facts

March 17 is widely accepted as the date of St. Patrick’s death in A.D. 461.

St. Patrick was born in Britain as Maewyn Succat. At age 16, he was

kidnapped from his home on the west coast and carried off to Ireland to

become a slave. After six years, he escaped. Upon returning home,

he spent the next 15 years preparing for his missionary work. When

he became a priest, his name was changed to Patricius,

and eventually, Patrick.


Interestingly, St Patrick was known for wearing blue.  He used the

shamrock to demonstrate how “the Father, the Son and Holy Spirit”

could be separate entities, yet one in the same.  Today, many people

associate the shamrock as representing Ireland, in fact the harp is the

symbol of Ireland.


Armed with these fun facts, let us celebrate this weekend to honor

St. Patrick.  Savor the boiled corned beef dinner.  Be swept up in the

Celtic music and toast this acclaimed patron saint of the emerald Isle.

Diode - Misunderstood Option2019-03-01

Diode – Misunderstood Option


di·ode  /ˈdīˌōd/  noun a semiconductor device with two terminals,

typically allowing the flow of current in one direction only. Diodes

are also known as rectifiers because they change alternating

current (ac) into direct current (dc).


There are times when an Request For Quote (RFQ) is received,

we enter the heater specifications into our heater configurator

and we are notified that the coil wire is too fine to manufacture.

In these instances we typically ask if two heaters of half voltage

can be used in a series connection. This typically allows the coil

wire diameter to increase up to 5 gauge sizes.


This is not always possible or desirable to the customer.  Or the

user may prefer our heater due to the exclusive “hot tip” feature

or because of bore seizure problems. In those circumstances,

using a diode in-line with one of the power lead wires may be a

great solution.


Installing an in-line diode with a resistor allows the current to flow

in only one direction.  This blocks the current when the polarity of

the AC voltage reverses and effectively reduces the wattage in half. 


With this in mind, we can double the wattage to increase the coil

wire up to the next gauge size and in many cases allows us to

wind a suitable resistance coil for the heater. This concept was

proven by one of our engineers who measured amperage of a

heater without a diode. And when a diode was added “In-line” to

one of the power leads the amperage was reduced in half.


Using Ohms Law:  Watts = Volts x Amperes this is confirmed.

Although diodes are rarely used, they can sometimes make the

difference between a sale and a referral to another heater. You

may want to discuss this option further with your Regional Sales

Manager  in order to discuss the particulars of using a diode

such as its’ size and the need to by-pass the diode to check resistance.





  Friday Funnies


Why did the diode kiss the capacitor – He couldn’t resistor


What do you call someone who steals energy – A Joule Thief


Why was the free electron sad – It had nothing to be positive about






Last year we hired a new ad agency to build a suite of new advertising

and promotional materials. They also created our new tagline –

“Trust the Dalton Difference”

We now have a series of advertisements that focus on our solution to

common problems customers face;  Bore Seizure, Uneven Heat,  

Reduced Cost of Heating, 50% Longer Lasting Heaters, and

Precision Heat for Super Savings.


Trust the Dalton Difference also means when you call, you reach a live

person, who knows you, who is helpful and knowledgeable. 

The difference also means quotes and orders are responded to

within an hour.  Our delivery is 3 weeks (not 4 to maybe 6 weeks).  

You also get our 100 years of know-how and unmatched quality and

performance giving maintenance managers other things to lose sleep over.


But what really separates Dalton from everyone else, is our ability to routinely 

perform the impossible. 


Yesterday a customer called in a dire emergency.  Their customer was

down and needed just one heater, it was both long and complex.  We sprang

into action.  We found a heater that was slightly shorter but could be used

in the application.  The heater was dried over-night, header welded, lead

wires attached and will be on a FEDEX plane this afternoon. 


Once again, Dalton does the impossible, crisis averted, and the legendary

Dalton Difference lives on.


Friday Funnies

Q:     How does a snowman get around?

A:     On an i-Cycle!


Q:     Where does a polar bear keep his money?

A:     In a snow bank!


Q:     Why don’t Mt. get cold in the winter?

A:     They wear snow caps!


Q:     What do snowmen eat for breakfast?

A:     Frosted Flakes!


Q:     What do you get when you cross a snowman and a vampire?   

A:      Frost-Bite


Spread the Love2019-02-15


Spread the Love!





    Friday Funnies

It’s Valentine week – make time for the one’s you love!

Q: What do squirrels give for Valentine’s Day?  A: Forget me nuts

Q: What did the Valentine’s Day card say to the stamp?  A: Stick with me and we’ll go places

Q: What is a ram’s favorite song on Valentine’s Day?  A: I only have eyes for ewe, dear

Q: What happens when you fall in love with a French chef?  A: You get buttered up            

PATRIOTS WIN 6th SB RING!2019-02-08






Defense wins championships!  The Super Bowl has never seen such a defensive battle as this year.   No one predicted

it – but what played out was an epic duel and test of wills to dominate the other.  Fortunately for us fans with zip codes

beginning with zero and despite the ill will from the rest of the world, the Patriots came out on top. This year’s game

pitted two of the best coaches in the NFL and possibly the best ever, against each other.


No question, Master YODA, Bill Belichick outmatched the tandem of coach genius, Sean McVay and coach

Wade Phillips.  For those defensive minded folks who marveled at the disguised looks, schemes and packages

thrown at the offense – it was a masterful chess match.  But in the end, it was experience and the fanatical attention to details,

practice, and more practice, and the art of doing one’s job that won out. 


Having grown up a Patriots fan my entire life, I have known the bitter taste of 2-14 seasons, TV black outs due to poor

attendance, and many other heartaches too painful to mention. I too tuned out and rooted for the underdog during past

dynasty’s.  Despair not, as this too shall pass.


Just as the Steelers final steel curtain call came to an end and the 49ers Montana/Rice reign came to a close, so too

will the Patriots duo of Belichick & Brady.  Until then, I kneel in thanks to the almighty, cheer gratefully for a team that

has cracked the code to winning in a league designed to bring parity – and there will be much rejoicing.





Friday Funny’s


TOP 5 Funniest Super Bowl Advertisements


5 – Pringles “sad device”


4 – Devour “premade meal addiction”


3 – Expensify “expensify this”


2 – Pepsi “more than ok”


1 – Skittles “advertising ruins everything”


Accessorize (part II)2019-01-25



Accessorize (Part II)



We are all familiar with axiom, “you are only as strong as your weakest link”.  This is certainly

true of a cartridge heater.  The weakest link in a cartridge heater is the termination point and

there are a great number of ways to protect lead wire and its termination to the heater.


If the heater is subject to substantial flexing, one first needs to ensure that the lead

wire is optimized for the size and rating of the heater.  Dalton Electric uses Grade “A” stranded

Nickel wire which provides much greater integrity than nickel clad or nickel plated copper.

Straight and right angle headers offer the optimum protection for lead wires.  These stainless

steel accessories will withstand all manner of abuse.  And they act as a transition from the

heater to stainless hose or braid.



Similarly, clip supports shield and protect from vibration or motion. Potting and sleeving are a

first defense in protecting the termination point and a header can be fully potted with Ceramic,

RTV Rubber or Glass, depending on temperature constraints.  This will fully encapsulate the

heater terminal and eliminate any stress points.  This painstaking attention to detail and superior

craftsmanship is the hallmark of Dalton’s Watt-Flex® cartridge heater.





             Friday Wisdom


Be advised that all flatterers live at the expense of those who listen to them

                                                                                    Jean De La Fontaine


How old would you be if you didn’t know how old you were?

                                                                                    Satchell Paige


Stepping Away2019-01-21

Stepping Away


After 33 years with Dalton Electric Heating Company, I will be retiring very shortly.  We have been blessed

to have had Chris Stevens with us for a year, shadowing me for much of that time and now overshadowing

me as he has assumed the role of President.  Chris brings a degree in Mechanical Engineering & MBA

and many years of Sales Management to Dalton and will provide a continuity that will be a seamless

transition in our effectiveness.


I have taken great pride and enjoyment in building a staff that is the most responsive and professional in

the marketplace and one that thoroughly enjoys working at Dalton.  And we have built a distributor and

customer network that has supported steady company growth over the years.  Our manufacturing staff

is completely dedicated to making the best performing heaters on the market and absence of turnover

reflects that dedication.



So I step away, with memories of professional triumphs, wonderful travel adventures and a host of

friends with whom I have had great pleasure sharing sales success and personal experiences.  So I now

serve on the Board of Dalton Electric and on the Board of a wonderful charity.  There are mountains to be

climbed, golf balls to be scattered around courses and curling stones to be thrown down the ice, trails to

be skied and ponds to be skated … and friendships to be maintained if you are ever up New England way. 

I will answer to This email address is being protected from spambots. You need JavaScript enabled to view it..  God Bless and Goodbye.



                                               Friday Funnies


“How lucky I am to have something that makes saying goodbye so hard.” — A. A. Milne, Winnie-the-Pooh


Retirement will be fun… I can get up at 6 o’clock in the morning and go drive around really slow and make

everybody late for work.

Accessorize (part I)2019-01-11


Accessorize (it’s functional and fashionable)


Contamination tops the list of heater failure.  That’s why it is always a good idea to protect your heater

investment by ordering lead wire protection and sealing configurations.  Contamination normally runs

along the lead wires (outside heat sink) toward the terminals or from inside the heat sink outward toward

the terminals.  Over the years, we have developed a host of solutions to stop contamination from

reaching the terminal pins and beyond. 


Our standard header is welded on one leg of the heater to allow for the leg of the other heater to expand

into the bore.  For applications where contamination moves up the legs of the heater, we offer a header

that is welded all the way around (weld around).  This keeps contamination away from the terminals where

it could cause problems.  In few severe applications, we offer a sealed collar configuration.  The collar is

swaged onto the heater near the terminal end.  This serves to prevent any contamination from working

its way between the heater legs and offers a full circular ring to weld the header on. 


To stop contaminants that drip, run along the wires, or wash down, we have a similar progressive approach.

The first defense is attaching a header and stainless BX hose to run the lead wires through.  If that is

insufficient, we can RTV pot the terminals.  If even greater resistance is needed, we can fully pot the header

with RTV – it’s a tedious time-consuming operation but has proven to be well worth the extra cost for those

demanding applications.


A well-dressed heater keeps contamination contained and lives on.



         Friday Funnies

The Dreaded Phone Call from the Boss…☹

My boss phoned me today. He said, "Is everything OK at the office?"

I said, "It's all under control. It's been a very busy day. I haven't stopped to take a break all day."

"Can you do me a favor?" he asked.

I said "Of course, what is it?"

"Pick up the pace a little - I'm in the group behind you."


Bore Seizure

Uneven Heat

Cost of Heating