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.

View the rest of the Maguire+Syncro range here.

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.

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.