Case Study Name

Challenge

A leading packaging manufacturer set out to revolutionize the poultry market with a recyclable, vacuum-sealed tray that could extend shelf life and meet the industry's high standards for food safety. Achieving this vision required precise, reliable heating control that conventional cartridge heaters simply couldn't deliver.

Conventional cartridge heaters posed three major barriers to success:

• Uneven heat distribution that lead to weak seals and product waste.
• Frequent heater failures that risked costly downtime.
• Inflexible designs that couldn't adapt to changing tray formats or production requirements.

To bring their innovative tray design to market, the manufacturer needed a new heating solution, one that could guarantee perfect seals at high speeds without compromising reliability.

Solution

Dalton Electric partnered with the manufacturer to engineer a custom cartridge heating system designed specifically for vacuum-sealed poultry packaging.

At the core of this solution was Dalton's Watt-Flex® split-sheath cartridge heating technology, engineered to deliver precision heating where standard designs fell short.

Key advantages included:

• Uniform, consistent heat for strong, reliable seals.
• Rapid heat-up and recovery times to maintain seal integrity at high production speeds.
• Custom-fit design and backend configuration for seamless integration with evolving tray formats and equipment.

By focusing on precision control, Dalton delivered a heater that wasn't just a component, but a critical enabler of the customer's packaging innovation.

Results

With Dalton's custom heating solution, the packaging manufacturer achieved:

• 2x increase in product shelf life, enhancing freshness and extending distribution potential.
• 100% seal quality maintained, even during high-speed production.
• Zero unplanned downtime from heater failures, ensuring smooth, continuous operations.

The outcome was more than improved performance, it set a new industry standard for reliability, efficiency, and packaging innovation in the poultry market.