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Packaging

In packaging operations, process heat determines more than efficiency, it defines product integrity, shelf life, and production reliability. From thermal sealing to thermoforming, packaging processes demand precise, uniform, and repeatable heat delivery to maintain seal quality, reduce scrap, and ensure compliance with strict food and product safety standards.

Dalton Electric's Watt-Flex® split-sheath cartridge heaters are engineered to provide unmatched precision and adaptability, enabling manufacturers to scale production without sacrificing reliability. These case studies highlight how leading packaging innovators overcame common heating challenges, and how Dalton's solutions are driving measurable improvements in seal consistency, throughput, and long-term equipment performance. 

Sealing the Future of Poultry Packaging

A leading packaging manufacturer set out to launch a recyclable, vacuum-sealed poultry tray that could extend product shelf life and raise the bar for seal integrity. Conventional cartridge heaters couldn't deliver the precision or reliability required. Dalton Electric partnered with their team to engineer a custom heating solution using Watt-Flex® split-sheath heating technology, resulting in doubled shelf life, flawless seal quality at scale, and zero downtime from heater failures.

  • Challenge
  • Solution
  • Results

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.

 

Challenge

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

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

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.

 

WATT-FLEX® VS. TRADITIONAL CARTRIDGE HEATERS

There’s really no comparison when you pit a traditional cartridge heater against the revolutionary split-sheath design of Dalton’s patented Watt-Flex®…at least in all the categories that matter. See for yourself why we’re the leaders in cartridge heater technology.

Watt-Flex® Cartridge Heater Watt-Flex® Cartridge Heater Watt-Flex® Cartridge Heater
Fast Even Heat | Faster Cycle Time & Less Scrap Fast Even Heat | Faster Cycle Time & Less Scrap Fast Even Heat | Faster Cycle Time & Less Scrap
Fast Even Heat | Faster Cycle Time & Less Scrap Fast Even Heat | Faster Cycle Time & Less Scrap Fast Even Heat | Faster Cycle Time & Less Scrap
Fast Even Heat | Faster Cycle Time & Less Scrap Fast Even Heat | Faster Cycle Time & Less Scrap Fast Even Heat | Faster Cycle Time & Less Scrap
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CUSTOM MADE SPECIFICALLY FOY YOUR APPLICATION

We have factory-trained sales agents and distributors throughout the world who are ready to assist you with your process heating applications. Please call or send us an email to get started.

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We have factory-trained sales agents and distributors throughout the world who are ready to assist you with your process heating applications. Please call or send us an email to get started.

Dalton Electric Heating Co, Inc.

28 Hayward St, Ipswich, MA 01938

PHONE
978-356-9844

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