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Medical device tray sealer

1830 Dual Shuttle

Two tooling shuttles serve the largest pneumatic platen in the range, 18″ × 30″, so one tool can be unloaded and reloaded while the other is in the sealing position.

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Heat sealing area
18″ × 30″
45.7 × 76.2 cm
Sealing force
Over 10,000 lb
Adjustable
Floor space
45″ × 72.5″
114 × 184 cm
Loading
Dual shuttle
Manual standard, automatic optional
Atlas Vac 1830 Dual Shuttle pneumatic tray sealer

Overview

Two loading stations on the largest platen

The 1830 Dual shares the 18″ × 30″ platen, 8″ dual-stage cylinder and precision surface plate of the 1830S, with a second tooling shuttle. While one shuttle is in the sealing position, the operator unloads and reloads the other.

Cycle 1Cycle 2Cycle 3Cycle 4
Shuttle 1 SealingReloadSealingReload
Shuttle 2 ReloadSealingReloadSealing
Operating sequence, shown schematically. Achievable cycle rate depends on your package, recipe and loading method.

  • Large-format tooling on each shuttle

    Each shuttle has mounting holes for two standard 15:18 tools or one standard 18:30 tool. Atlas Vac confirms fit for each package.

  • Plan for the full length

    A 45″ W × 72.5″ L machine footprint. Installation and service clearances are confirmed for each order.

Atlas Vac 1830 Dual Shuttle tray sealer, side view in the workshop
Side view

Specification

Standard specification

Values describe the standard 1830 Dual pneumatic configuration. Electrical supply is specified at order; optional equipment may change the arrangement shown in drawings.

Sealing

1830 Dual
Heat sealing area 18″ × 30″ (45.7 × 76.2 cm)
Tool-height opening Up to 4.5″; others on request
Sealing force Adjustable to over 10,000 lb
Press Pneumatic, 8″ diameter dual-stage cylinder
Heat plate Flat 1″ plate with internal heaters, 6,000 W, 240 V or 480 V
Seal platen Precision-machined aluminum, DuPont Teflon Silverstone coating included
Surface plate Blanchard-ground, nickel-plated steel, flat to .001″–.003″

Machine

1830 Dual
Loading Manual dual aluminum shuttles on 1″ stainless shafts
Tooling shuttles Quick-change lift-off shuttles with stainless steel locator pins
Floor space 45″ W × 72.5″ L (114 × 184 cm)
Frame Welded 3/16″ steel tube, white powder coat; NEMA 12 enclosures under the frame
Mobility Non-mar casters with height adjustment and brakes
Staging Stainless eye-level shelf with under-shelf LED lighting
Weight To be confirmed

Utilities

1830 Dual
Electrical 208, 220/240, 380 or 480 V; single or three phase; others on request
Compressed air 11–13 CFM at 80 PSI, measured at 4 cycles per minute
Air supply 100 PSI on a ¾″ minimum line; 5 micron inlet filter
Air reservoir 4.7 gallon ASME or 25 L CE, with certified relief valve
Exhaust Single port with 20 micron filter or room discharge connection; sound levels comply with OSHA 1910.95
Power cable 9 ft, ready for a customer-supplied plug

Safety

1830 Dual
Cycle start Two-hand Banner Opti-Touch safety-rated sensors, per OSHA 1910.212 and 1910.144
Isolation Pneumatic CE safety-rated isolation lockout valve
Guarding Stainless operator guards on Auto Shuttle models, meeting OSHA 1910 Subpart O, 1910.145, EN 415-1 and -3, and ISO 12100:2010
Emergency stops Stationary yellow/red safety shields; meet CE, UL, CSA, OSHA and ISO 13850
Controls design NFPA 79 compliant
Touch protection Components compliant with IEC 60204-1, and with CE, CSA and UL as applicable
Overtemperature Redundant automatic heater cutoff, Factory Mutual approved controller, 300°F standard

Floor space is the machine footprint; additional room is required for installation and service access. Heater rating covers the platen heaters only, not the total connected electrical load. Air consumption is rated at a test condition, not at a production rate.

To be confirmed Awaiting confirmation

Standard controls

Shared controls for both loading stations

One PLC and 10″ touchscreen manage the press for both shuttles, with password-protected recipes, alarm limits and sign-in levels for operators, supervisors and calibration staff.

Records, data export and integration

  1. Control platform

    • Mitsubishi FX5u PLC
    • Beijer 10″ color touchscreen at eye level, storing multiple recipes
    • English (default) or metric readouts

  2. Recipes and access

    • On-screen time and temperature control with alarm limits
    • Supervisor, engineer and calibration sign-in levels
    • Individual operator sign-in (optional)

  3. Pressure

    • Precision manual regulator with liquid-filled gauge
    • On-screen digital pressure readout
    • Pressure calibration port with on-screen calibration

  4. Calibration

    • Four dual-lead thermocouples with individual calibration ports
    • On-screen, password-protected thermocouple calibration
    • 24 VDC timer calibration connector

  5. Data and traceability

    • Logging of sign-on, recipe changes, UDI and process data on every cycle
    • USB data offload; records cannot be edited
    • Two powered USB ports for a barcode scanner (not included); manual entry on screen also permitted
    • Recipe matching to barcoded tooling and device paperwork

  6. Monitoring and alarms

    • Temperature and air pressure fail-safe alarms
    • Alarm detail history on screen and in memory
    • Multi-color LED signal light
    • Odometer and resettable cycle counter

Options

Configure your 1830 Dual

With two stations to load, automatic shuttle motion and a light curtain let the operator work while the press cycles. Both options are documented in their own drawings.

How each option works

Standard

Supplied with every 1830 Dual

  • Manual dual shuttles
  • Manual regulator with digital readout
  • Air reservoir and isolation valve
  • Staging shelf with LED lighting
  • FX5u PLC and 10″ touchscreen

Ready for operation on connection to air and electric power.

Foundation options

Enable the advanced options

  • Auto Shuttle System

    Electrically drives both shuttles with smooth, single-speed acceleration and deceleration. Adds stainless steel side guards over the shuttle bearings. Interlocked with the hand sensors or the optional light curtain, it reduces repetitive operator motion and abrupt movement of tray contents.

    The press remains pneumatic.

  • Auto Pressure Control

    Closed-loop air pressure control set from the touchscreen, upgrading the standard manual regulator.

    Regulates the air pressure to the press. A digital lb-f force reading is available as an option.

Advanced options

Each lists the options it requires

  • Class 3 vertical light curtain

    OSHA and CE compliant, across the horizontal tool loading area, with separate safety circuitry and dual-channel Ross safety-rated valves. A single green push button replaces the hand sensors, and any interruption returns the cycle to home. The operator can work while the cycle runs.

    Requires
    Auto Shuttle
    Auto Pressure

  • Direct Force Sensing

    Patented digital reading of the force in lb-f applied across the tool face, shown on the operator screen. Specifying lb-f in a sealing protocol accounts for differences in air pressure, sealers and tooling, and supports validation experiment set-up. For reference; not a closed-loop control.

    Requires
    To be confirmed

  • Auto Eject Tooling System

    Pneumatic lift of sealed trays as the shuttle returns home, with adjustable 1–10 second dwell. The sealer also runs non-eject tooling.

    Requires
    Auto Shuttle
    Atlas Vac eject tooling

  • Seal Tool Recognition (RFID)

    An RFID chip in the tooling verifies the correct PLC recipe on every cycle.

    Requires
    Process Control

Further options

  • Stainless steel framework and controls cabinet
  • Horizontal light curtain arrangement (see drawing 592022-SK)

Tooling

Tooling machined for the 1830 Dual

Atlas Vac designs and CNC-machines tooling nests for each package. Tooling is quoted separately from the sealer.

Tooling

  • CNC-machined lift-off nests

    Rigid aluminum nests machined to lock into place quickly on each shuttle. Anodized as standard.

  • Seal gaskets

    Molded FDA silicone gaskets for easy changeover, or die-cut silicone gaskets for some configurations.

  • Relieved hot plate option

    Reduces heat transfer to product in the middle of the tray where it touches the lidding material.

  • Retrofit tooling

    Design and retrofit services for non-Atlas Vac sealers, including Alloyd and others.

Drawings and documents

Configuration drawings

Three dimensioned drawings cover the Auto Shuttle and both light curtain arrangements. Each applies to the configuration shown; Atlas Vac confirms the drawing for your ordered configuration.

Supplied with every 1830 Dual

  • Owner’s manual with operation and maintenance information
  • Recommended spares list
  • Schematics and the Atlas Vac calibration document
  • Atlas Vac PLC programs on USB flash drive

Tooling nests are quoted separately. Factory acceptance testing and additional documents are quoted by scope.

Tooling

In the range

Related models

Compare all six models

Project enquiries

Discuss your 1830 Dual application

Our engineers will review your package and production requirements and recommend the 1830 Dual configuration and tooling that suit your process.

Useful if you have it

Tray drawing or sample tray · Lidding material · Options of interest

Request a consultation +1 (513) 407-3513
Address
Atlas Vac Machine, LLC
9150 Reading Rd
Cincinnati, OH 45215, USA
Phone and email
(513) 407-3513
sales@atlasvac.com
Hours
Mon–Fri 08:00 am – 05:30 pm
Saturday by appointment
Sunday closed