Custom Engineered Medical Device Tray Sealers, Indexing Sealers and Thermoformers
Our standard features as well as our patented options, come from customer input. Our engineers listen and this is why Atlas Vac Machine sealers have the features that packaging professionals seek. Make the clean room operator happy by providing the options that enhance throughput.
The shuttle and attached tool is moved under the under the heat platen for the sealing cycle by the operator using a forward hand motions. The operator then activates the sealing platen by inserting both hands, simultaneously, into the Banner Optitouch sensors. The PLC controls the platen down stroke, seal time and release. Once the platen releases from the tool, the operator can withdraw the shuttle back to the "home" position for the operator to unload. The operator must first be sure the platen has lifted prior to moving the shuttle or the platen may break spring pins on the tooling. Note: The operator's hand must remain in the Optitouch sensors until the platen closes on the tool. Once the platen is in contact with the tool, the operator may remove hands from the Optitouch sensors and begin preparation of another tray to be sealed on the next load.
Electrically driven shuttle actuators are used to cycle the shuttle and seal tool under the platen for the sealing cycle and subsequently returns the shuttle to the "home" position for the operator to unload. The operator activates the shuttle by inserting both hands, simultaneously, into the Banner Optitouch sensors to begin the sealing cycle. The ultrasmooth electric drive system is pre-programmed for accel and decel as well as velocity. The Auto Shuttle feature is standard on the All Electric Model 18:30S.
As always, the PLC controls the platen down stroke actuation, seal time and release. At the end of the seal cycle, the auto shuttle is returned to the "home" position by the operator using the safety hand sensors. Note: For approved safety requirement, the operator's hand must remain in the Optitouch sensors until the platen closes on the seal tool. Once the platen is in contact with the tool, the operator may remove hands from the Optitouch sensors and begin preparation of another tray set to be sealed on the next load. Click here.
Also see our Category 3 Light Curtain system for total automatic shuttle movement with the push of one button. Click here.
Provides horizontal or vertical light curtain across protected tool loading area. ISO13849, Class 3+ OSHA and ESA compliant with separate safety circuitry. Designed to meet those corporate standards where a "zero access" requirement is cited. Light curtain system integrated to press air supply valve and electric shuttle motion circuit for operator access safety. Any light curtain violation will require the cycle to re-home and start over. Eliminates the standard Banner Optitouch hand sensors which are replaced by single green push button to initiate the entire cycle automatically.
While the sealer completes the entire cycle safely, the operator can prepare the next load internal to the current cycle time. A significant gain of productivity while eliminating repetitive motion fatigue of a standard push/pull manual shuttle.
Operationally, the product and tray materials are loaded in the tool, the operator presses the green start button and the electric auto shuttle cycles into position, seals, releases, returns to the home position. Standard single channel Festo press pneumatic control valves are replaced by dual channel Ross safety rated pneumatic control valve system. Requires the Auto Electric Shuttle & Auto Pressure options. Standard single channel pneumatic control valves are replaced by dual channel Ross safety rated pneumatic control valve system. Auto Pressure regulation is still provided by standard Festo system.
Light Curtains are standard equipment on Atlas Vac Model 1830S All Electric Tray sealer.
Measure "down force in lb-F" not just air pressure...only with Atlas Vac. No other medical device tray sealer on the market can directly measure the force exerted by the sealing platen. You validate time and temperature but why are you validating supplied air pressure instead of the actual Force against the seal tool?
Now packaging engineers can refine their validation efforts by starting with the lb-F needed to seal a known flange surface area.
Only Atlas Vac Machine offers the correct instrumentation to measure the “down force” or “lb-F” output of the tray sealer. Our patented Direct Force Sensing option is available on all our models.
Direct Force Sensing System (patented) provides a reading of the force (lbs.-force) exerted by the tray sealer press against the seal tooling on every stroke. Results from adjustments in press air pressure can be directly read on the PLC operator screen. By knowing the lbs-f exerted across the tray sealing tool face, packaging engineers can more closely monitor design variables. Defining the desired lbs-f in a tray sealing protocol can accommodate variations in air pressure, brands or models of tray sealers, and even tooling designs. Variations between sealers, packaging lines and even multiple manufacturing sites can be harmonized by "dialing in" to the defined Force.
Air pressure is the input. Force is the output!
Are you measuring the input air pressure on your tray sealer? Why?
Air pressure is set by a precision manual regulator and displayed on the PLC screen through a pressure transducer signal. This same screen is where the high & low pressure limits are set by password enabled input to control the process through the validated protocol. Pressure setting is maintained at all times by the manual regulator. Alarms prevent operation outside the limits.
Atlas Vac offers a Process Control option where the air pressure setting is entered directly on the same PLC screen as the high & low pressure limits. This provides a "cruise control" feature where the PLC electronically maintains the air pressure to this digital setting. This closed loop system provides accurate psi (or bar) readings on the screen as well as the ability to set the nominal setting on the set-up screen. The operator can adjust pressure settings only between the locked limits. Alarms prevent operation outside the pre-set high or low limits. We use Festo brand for our automatic pressure control.
The Atlas Vac Tool ID (RFID) System, the first in the medical device industry over 25 years ago, enables the packaging engineer to imprint each tool with a distinct recipe identity. It is therefore matched to the correct PW protected validated recipe.
This imprint, as well as overwriting capability, is password protected on the Atlas Vac sealer. The operator using these tools must select the correct recipe, as demanded by the RFID equipped tool, or the sealer will not cycle.
For those packaging rooms where several products interesect at one medical device tray sealer, this enhances productivity where the operator can be empowered to flawlessly make several tooling and product changeovers throughout the day without requiring the assistance of a supervisor and/or password. This is an option on all Atlas Vac sealers since some customers do not need this feature due to single product use on a dedicated sealer.
Note: For those customers wishing to match a tool to a recipe and a third item such as a traveler document, our UDI feature available on the recipe screen can match a tool barcode to the recipe as well as the documentation. Such barcode matching capability is standard on all Atlas Vac sealers.
Atlas Vac offers an Auto Eject System (optional) for gentle automatic lift ejection of sealed trays as the Auto Shuttle System (option required) returns the completed packaging and tooling to the home position.
No hardware, no claptrap, no repetitive motion issues for operators.
The eject timing can be adjusted from 1-10 seconds hold duration. This option has a pneumatic system built into the tray sealer and requires matching Atlas Vac tooling. Yes, you can still run your older tooling without the lift system.
A manual eject command is also included. Retrofits can be provided on select Atlas Vac medical device tray sealers and tooling sets. Please provide us with your Atlas Vac s/n and tooling assembly part number.
Auto Shuttle with Auto Eject of trays, test video, auto and manual operation featured (click here)
Videojet printing system integrated with Atlas Vac electric auto shuttle to print data on lidstock as sealed tray exits the press area. Any data from recipe seal stroke readings, audit file data, lot codes, etc available for lid printing.