Cleanroom sealer Audion Powersealer IST TC / MEDPLUS

Cleanroom sealer Audion Powersealer IST TC / MEDPLUS

The Audion Powersealer IST TC / MEDPLUS is an advanced stainless steel bi-active impulse sealer for cleanrooms. With active temperature control (ATC), recipe management, and USB data logging, this pneumatic sealer (compressed air required) offers maximum

The Audion Powersealer IST TC (PSR TC series) is a high-quality industrial impulse sealer in a robust wide body design, engineered for organisations and cleanroom environments that demand maximum control, precision, and reproducibility within their packaging process. The machine is constructed entirely from high-grade stainless steel (AISI 304) and features pneumatically driven bi-active, flat seal bars. Thanks to the renowned “open head design”, bags can be inserted quickly and effortlessly, which significantly increases operational efficiency.

Important installation requirement: For the operation of a Power sealer, an external compressed air connection is always required (0.6 – 1.0 MPa / 6 – 10 bar).

The integrated Audion Temperature Controller (ATC) continuously monitors and regulates the seal temperature (100 – 200 °C, accurate within ± 3 °C or ± 2%). This guarantees a consistent, high-quality, and airtight 8 mm wide seal seam on virtually all modern packaging materials with a film thickness of 2 x 20 to 2 x 200 microns. The Powersealer IST TC is available in three seal lengths: 520 mm, 720 mm, and 1020 mm (also available as a vacuum variant VAC PSR TC). For regulated markets where strict process validation is essential, a certified validatable version is available in accordance with standards such as ISO 12100, ISO 4414, ISO 14118, and EN 60204-1.

The Audion Powersealer IST TC/ MEDPLUS combines the user-friendly Audion Touch Techware interface with a powerful 7" HMI. This allows operators to quickly switch between 50 pre-set recipes, minimising downtime and eliminating input errors.

In addition to real-time error and status notifications on the screen, the machine records every seal cycle in detail. To ensure a constant and powerful closing force of the bi-active seal bars, the closing mechanism operates pneumatically. An external compressed air connection of 6 to 10 bar (0.6 – 1.0 MPa) is therefore always necessary.

Key features and benefits

• Advanced temperature and process control: The Audion Temperature Controller (ATC) precisely manages the seal temperature (100 – 200 °C with adjustable tolerance of 0 – 20 °C), seal time (0.8 – 10.0 sec.), and cooling temperature (50 – 150 °C). If deviations occur outside the tolerance range, an automatic parameter alarm-stop is triggered.
  
  
• Bi-active pneumatic seal bars: Simultaneous heating on the top and bottom ensures a powerful, uniform 8 mm seal seam on both thin and heavier laminate films.
  
  
• Audion Touch Techware on 7" HMI: Intuitive colour touchscreen with memory capacity for up to 50 programmable recipes, adjustable in 8 languages (Dutch, English, German, French, Italian, Czech, Japanese, and Chinese).
  
  
• Secure user levels: Access control with 3 levels (Operator, and password-protected Supervisor and Administrator) prevents unauthorised changes to seal settings.
  
  
• Extensive data logging and traceability: Easy export via the USB connection to a .csv file. Logged parameters include Machine ID, login level, recipe name, batch number, set parameters, tolerances, alarm limits, date/time, Seal ID, parameter results, pass/fail status, and alarm codes.
  
  
• Built-in counters and alarm history: Equipped with a resettable bag counter, a non-resettable machine counter, and a complete alarm log with date, time, and error codes.
  
  
• Cleanroom-compatible & safe design: Fully smooth stainless steel AISI 304 construction that is easy to disinfect and minimises particle emission. Equipped with an electric foot pedal and an easily accessible emergency stop.
  
  
• Wide expansion possibilities: Configurable with cleanroom options (SILA silicone arm, ESD safety, external exhaust, particle filters), integrated cutting device, bag stretchers, support tables, adjustable stands, and options for vacuum and gas flushing (MAP).

Technical specifications

Optional validatable features for demanding applications

For organisations within the pharmaceutical industry, medical technology, and/or high-tech environments, the Audion Powersealer can be supplied as a certified validatable device, indicated by the addition MEDPLUS. If you choose a MEDPLUS system, Audion provides periodic, annual validation and calibration on-site by a certified Audion technician/specialist. During this inspection, all measurement and control values are thoroughly checked and calibrated to ensure that the device continues to meet official factory specifications. This guarantees the reproducibility of your packaging process and ensures you have the required audit documentation and certification for quality audits at all times.

Audion Powersealer IST TC / MEDPLUS vs. Industrial Sealmaster (ISM)

Although both the Powersealer IST TC and the Industrial Sealmaster (ISM) are equipped with a hygienic stainless steel housing for industrial and controlled environments, they are designed for significantly different application levels and process requirements:

• Pneumatic closing vs. electromagnet: The Powersealer uses a pneumatic closing mechanism via external compressed air (6 – 10 bar). This provides a significantly higher, constant, and uniform closing pressure over the entire seal length. The ISM, by contrast, works with an integrated electromagnet (no compressed air required), which makes it more compact and plug-and-play, but less powerful for heavy industrial loads or thick laminate films.
  
  
• Bi-active seal bars vs. single-sided impulse: The Powersealer is standard equipped with bi-active seal bars (both bars are heated simultaneously) with an industrial seal seam of 8 mm wide. As a result, the Powersealer effortlessly seals heavy multi-layer films, barrier films, and thicknesses up to 2 x 200 microns (or more). The ISM seals with a single-sided impulse (seal seam of 3 or 5 mm), ideal for standard polyethylene (PE) or polypropylene (PP) bags up to approximately 2 x 150 microns.
  
  
• ATC temperature control vs. time-controlled timer: The Powersealer features an active Audion Temperature Controller (ATC) that measures and regulates the actual seal temperature (100 – 200 °C with ± 3 °C accuracy) and only opens when the set cooling temperature has been reached. The ISM operates purely on the basis of time control (analogue or digital timers) for seal time and cooling time, without active measurement or control of the physical temperature.
  
  
• Validatability and data logging: The Powersealer offers full process assurance via the 7" touchscreen, including 50 programmable recipes, 3 secure access levels, alarms with process stop, and USB data logging (.csv). In addition, the Powersealer is available in a certified validatable variant in accordance with medical and GMP guidelines. The ISM is a robust production machine for daily packaging, but does not have recipe memory, audit trails, or validation options for qualified cleanroom processes.
  
  
• Size and ergonomics: While the ISM is available up to a seal length of 620 mm, the Powersealer offers wider dimensions up to 1020 mm, a larger bar opening (45 mm), and an ergonomic open head design for the fast and repetitive processing of larger batches.

For maximum reliability, Audion offers a Factory Calibration Service and seal integrity tests (including peel tests, seal checks, and ink penetration tests).

Combine the Powersealer with our cleanroom consumables and cleanroom work tables for an integrated, controlled packaging line.

Do you have questions about the compressed air requirements, would you like advice on the correct seal width (520, 720, or 1020 mm), or are you looking for support with the validation of your packaging process? Please contact one of our cleanroom specialists.