Saturn Atlas Manual
Profile Control System

To Retrofit Stationary Blown Film Dies / Air Rings

Reduce point to point variations
Retrofits any air ring
Controls target zones on substrate
Achieve gauge uniformity

Segmented sections available to suit any die size
Operates independent of air ring
Unbeatable return on investment (ROI)

The Future Design Saturn Atlas is a segmented device which has been calculated to deliver a specific volume and velocity of air to a localized position on the blown film bubble stalk as it exits the die. The segmented apparatus is attached to the underside of the air ring lower lip. It is installed at the factory to ensure concentricity with the air ring and is adjustable to the precise location on the die. Each segment is fed from an independent poly tube and a specific flow control valve to manipulate the airflow precisely. This will change the polymer-cooling rate to achieve the best possible profile.

Once the highs and lows of the film have been determined using an on-line or off-line profiler, the system can be activated. The profiler can be supplied by Future Design or can retrofit an OEM gauging system. Dependant on the number of segments the system contains, each zone can add or reduce air-cooling to the local area and influence the gauge thickness.

Quite frequently, a die will distribute a polymer unevenly. The regions of the die where there may be too much polymer being extruded causes the resulting bubble in this region to retain its heat properties due to this thickness. The film in turn continues to expand at these points, becoming thinner at the frost line. This affects the cooling rate and quality of this section of the film creating low spots or thin spots.

Conversely, when a portion of the die distributes too little polymer, it allows this section of the film to cool faster. The film then retains a portion of its original thickness, thus creating thick spots on the film.

With the addition of the Saturn Atlas, we are able to control sections of the film by providing an insulated current of air. This insulation allows the bubble to continue its expansion, bringing it closer to the ideal gauge.

A control panel with each target zone identified, allows the operator to control the flow valves, which will distribute the air to each individual segment. The results will be visible on the frost line of the bubble and will be verified with the polar plots of the film profiler.

The cost of the Atlas system can be justified with its direct return on investment. Savings will be realized through the reduction of gauge variation percentages, resulting in reduced resin consumption and film scrap. Further results will produce film throughput increases, labor reduction and a decrease in energy cost and consumption.

If there is an interruption due to the maintenance of the Saturn Atlas System, it operates independently from the primary cooling functions of the air ring, and the system will continue to run at full capacity.

Benefits of the Saturn Atlas System:

Reduces point to point gauge variations by as much as 50%
Retrofits to any air ring
Controls target zones on the substrate for almost any polymer application
Achieves film uniformity
Unbeatable return on investment (ROI)

Includes the following:

Special mounting ring is supplied to suit the specific make-up of the customer's die. This will locate the air ring using a fine-threaded adjustment to gain concentricity with the die.
High-precision polycarbonate flow control valves mounted into the single control panel.
Relative group of poly tubes (10 foot lengths supplied) from the control panel, to be contained in sets to the segmented ring.
The segmented ring is attached to the air ring bottom lip and is ready to accept the supplied poly tubes.
Each poly tube is identified for quick connection and specific location on the segmented ring.
Pressure is regulated with an A/C Frequency controller installed on a specialized pressure blower. Intake filters and silencer are installed.
Stand-alone panel will contain a pressure blower and each individual controller will be identified to correspond with a real time location on the air ring.

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Please contact Future Design if you have any questions,
or if you would like a quotation for the Saturn Atlas Manual Profile Control System.

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