Heated Platen Press

Challenge

A U.S. manufacturer operating a heated platen press was under pressure to improve consistency, reduce scrap, and cut unplanned downtime. Their process relied on low-cost imported heaters that, while similar on paper, couldn’t deliver the precision or reliability the operation demanded.

Production teams battled ongoing problems:

• Frequent heater failures disrupted production and consumed labor hours.

• Uneven temperature distribution across the platen caused hot and cold spots.

• High scrap rates drove up material costs and reduced yield.

• Unplanned downtime impacted throughput and delivery schedules.

• Supply chain risk from imported components created uncertainty and delays.

As performance declined, the team faced a critical decision: continue replacing failing heaters or invest in a higher-performing solution designed for long-term process control.

Solution

After months of chasing “low-cost” heaters, the team realized cheap wasn’t cheap anymore. Every failure cost time, product, and trust.

So they stopped bargain-shopping, and started investing in performance. 

Dalton Electric partnered with the manufacturer to replace the imported heaters with Watt-Flex® split-sheath cartridge heaters, engineered specifically for uniform platen heating and extended operational life.

The difference came from design:

• The split-sheath construction expands to make full bore contact, delivering efficient and consistent heat transfer.

• Uniform temperature distribution across the platen eliminated cold zones and improved seal and press quality.

• Longer service life minimized maintenance interruptions and replacement costs.

• Domestic manufacturing and support ensured reliability and short lead times.

By focusing on full-contact heat transfer and long-term durability, the Watt-Flex solution transformed the platen press from a maintenance burden into a stable, high-performing asset that supported production goals instead of limiting them.

Results

The improvement was immediate and measurable. Within the first operational cycle, the manufacturer saw clear performance gains:

• Consistent platen temperatures led to reliable, repeatable product quality.

• Dramatically longer heater life reduced maintenance costs and downtime.

• Scrap reduction improved material yield and reduced waste.

• Increased uptime supported higher throughput and delivery consistency.

• The investment delivered a 40% return on investment, proving that premium process heat delivers lasting financial and operational value.

For this manufacturer, upgrading to Watt-Flex wasn’t just a change in components, it was a shift in philosophy. Process heat was no longer a consumable cost; it became a strategic advantage in efficiency, reliability, and profitability.