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IBC & Layflat Control

Internal Bubble Cooling (IBC) is designed to automatically control and manage blower balance and increase cooling efficiency. 

  • Non-contact, ultrasonic IBC bubble control
  • Precise layflat control
  • Waste reduction during start-up and changeover

Why Upgrade IBC

Another critical factor on from materials blend and extrusion control for the performance of a blown film line is the IBC (Internal Bubble Cooling), with integrated auto width control for the layflat.

Upgrading a line without IBC & Layflat Control, or a line with a dated simpler system can deliver significant performance benefits for any blown film line.

Maguire + Syncro offer SYibc, which is a convenient and effective package for IBC and automatic Layflat Control. A processor can upgrade as a standalone product or integrated as part of the program of modular upgrades for improving performance on a blown film line from Maguire + Syncro range of products.

To enable fast and accurate control of a layflat width the SYibc uses a triangulation of 3 non-contact ultrasonic sensors, with a separate calibration sensor to moderate for ambient conditions. This data provides constant readings to the IBC PLC control, and enables the IBC stepper-controlled valves to be precisely regulated for fast and consistent control of the internal bubble cooling airflow.

Upgrading your line with Maguire +Syncro SYibc can quickly deliver these core benefits:

  • Improved control and increases production rates.
  • Optimize layflat control to less than ± 2mm of target set for LayFlat width control.
  • Increase internal cooling rates - increases production and process consistency.
  • Edge trim and startup waste reduced – reducing materials costs.
  • Reduce manual interventions and setup.
  • Easier product changes and quicker setups and startups.
  • SYibc applicable for all types of IBC die, EasyWidth for non IBC - compressed air dies.
  • Temperature compensation manages 24-hour ambient fluctuations.
  • Cost effective to deploy - typical return of investment within 12 months.

IBC Layflat Control Benefits

Ultrasonic Layflat Sensors

  • Optional ultrasonic distance sensors.
  • Mounted on top of cage where bubble is already formed.
  • Controls automatic opening & closing of cage.
  • Improved layflat width control to less than ± 2mm.

Ambient Temperature Control

  • Ultrasonic sensor installed at a fixed distance.
  • To control ambient temperature variations.

Ultrasonic Gap Sensors 

  • Mounted on bottom of the cage.
  • Maintain distance between bubble and moving cage.
  • Measure instant bubble dimension variation.
  • To avoid deflation of bubble.

IBC Control Valve

  • Unique bypass valve to improve flow control.
  • Valve installed on T pipe.
  • Improved accuracy in bubble stability.
  • Customized stepper motor.

Maguire + Syncro Control Flexibility

  • Convenient operation and analysis via Syntrol Plus Supervisory System.
  • Rapid detection and response for optimum width stabilization.
  • Waste reduction.
  • Improved bubble stability.
  • Faster and simplified operator control.
  • Possibility to store all key process setup parameters.

How an IBC Control Upgrade Pays

Return on Investment

  • Improved control and increases production rates by 10% to 40% depending on line process and material, compared to a line without IBC control.
  • 5% to 15% gain versus simpler old IBC control systems by better automation, regulation control, and data.
  • Reduction of wastage in edge trims, reduction in handling and recycling costs.
  • Reduction of labor interventions and management of the IBC.
  • Gains on start-up / reduction in materials scrap and wastage.
  • Easier product changes and quicker setups and start-ups.
  • Optimizes overall process with quick and effective control.
  • Cost effective to deploy - typical return of investment within 12 months.

1. IBC Control Valve

Unique bypass valve improves flow control and improves accuracy in bubble stability.

3. Increase Production Rates

Production rates are increased by 10% to 40% depending on line process and material, compared to a line without IBC.

5. Ultrasonic Layflat Sensor

Ultrasonic distance sensors controls automatic opening & closing of cage.

123456Photo of IBC & Layflat Control

2. Rapid Return on Investment

5% to 15% gains versus simpler old IBC control systems by better automation, regulation control, and data.

4. Optimize Layflat Control

Optimize layflat control to less than ± 2mm of target set for LayFlat width control.

6. Ambient Temperature Control

Ultrasonic sensor installed at a fixed distance to control ambient temperature fluctuations 24 hours a day.