IS-IBC1 Internal Bubble Cooling Control System (patented)
The IS-IBC1® provides the highest possible product rates while still maintaining tight layflat control. The IS-IBC1 Internal Bubble Cooling control system is very flexible and comes with the widest variety of configuration options available in the industry. Some of the configurable features include automatic startup, automatic on-the-fly size changes (including sizing cage control), and industry standard communication interfaces. Every system is made-to-order to match the application. In addition to the main components, every system also comes with all signal wiring with military style quick connectors for fast installation.

Standard
The standard IS-IBC1 system is the most economical system DRJ provides. This system is recommended for more experienced blown film operators. The system provides bubble size control with electronic adjustment for bubble contact with the sizing cage. This model can be field upgraded to include auto blower balance, layflat controller and auto cage control.

Auto Blower Balance
The IS-IBC1 system with automatic blower balance coordinates all blower control functions automatically eliminating the need for operators to be trained on balancing or nulling the blowers. The control panel includes integrated blower and air exchange controls. This model can be field upgraded to include layflat controller and auto cage control.

Layflat Controller
The IS-IBC1 system with layflat controller adds a second feedback loop to further reduce long term layflat variation. A color touch screen interface is included. Layflat is automatically set when the operator enters the desired layflat. Only the sizing cage is manually adjusted by the operator. This model can be field upgraded to include auto cage control.

Auto Cage Control
The IS-IBC1 system with automatic blower balance coordinates all blower control functions automatically eliminating the need for operators to be trained on balancing or nulling the blowers. The control panel includes integrated blower and air exchange controls. This model can be field upgraded to include layflat controller and auto cage control.



Seal Cut - High Quality and Versatility
High Quality Side Seals

The new high-speed Seal-Cut sealing system for plastic film offers an original, innovative solution for machine direction sealing. The Seal-Cut is capable of producing high quality, sealed edges in a wide variety of film applications. The stand-alone design allows it to be free standing or easily attached to winders, bag-making machines and rewinders.

Versatility

The Seal-Cut is capable of converting large jumbo or master rolls into smaller poly bags. This saves production and equipment costs because you can run several small size poly bags on one larger line rather than needing several smaller lines to run the same amount of bags.

Safe

The seal-cut uses a non-sharp sealing element and has no driven parts. All high temperature and pinch points are clearly labeled.

Performance and Benefits
  • Fastest Line Speeds in its Class - Up to 820ft/min (250m/min)
  • Film Thickness' up to .006 inches (150 microns)
  • Low or No Static Build up of the Film
  • Simple Design Concept
  • Consistent and Reliable
  • Convert Master Rolls into Several Smaller Sized Rolls
  • Reduce Production & Equipment Costs
  • Supports up to 6 seal stations per unit

Background
The Seal-Cut reverses the process commonly known as slit-seal. Instead of slitting the material and then sealing it, the material is first preheated, then sealed and then split. This results in a clean seal, even on material up to 6.0mil. For most materials, we use a significantly lower sealing temperature than the hot knife systems. For instance, a hot knife is usually set between 700 and 900F. The Seal-Cut is set at about half that temperature. The benefits of using a lower temperature is the polymer is not crystallized. The result is a high quality seal that has excellent strength along the seal edge in both the transverse and machine directions.



Variable Speed Drives
Variable speed drives allow the operation of any IBC system to be more user friendly and much more efficient when compared to systems using manual damper valves and fixed speed blowers. The precise control allows operators to make fine adjustments that are nearly impossible using damper valves. The fine adjustments can mean the difference between a stable bubble and an unstable one. However, there are several considerations that should be investigated before selecting the drive.

Not all drives are created equal. There is a variety of features available that may or may not be necessary for the IBC application. In this case, the general application is a fan. This most commonly calls for a general purpose, variable torque drive, with linear ramping, coast to stop, and at least one configurable dry contact used to report drive faults. Other features, including interface protocols are also available at extra costs. Review the headings below for additional information on the most common VSD concerns

Flux Vector or General Purpose
Flux vector drives promise very tight speed control tolerances, but there is significant effort required to achieve this performance. For fan applications, the fan has to be separated from the blower motor and calibrated. This takes considerable time and the value is difficult to justify. DRJ successfully uses general purpose drives for all IBC applications.

Variable or Constant Torque
Variable speed drives come in two varieties, constant torque and variable torque. For all IBC and airing fan applications, variable torque is sufficient. This is because at low speeds, the fan requires very little torque to initiate spinning. Generally speaking, the variable torque drives are less expensive.

Capacitor Banks and Braking Resistors
As drives become available at lower costs and the drive packages getting smaller, the limited ability to dissipate energy can cause nuisance trips that shut down the extrusion line. The specific fault is over voltage on the DC buss. Plan on purchasing the braking resistor kit for these small package of drives. Contact us if you have any questions about the drive you are considering.



Internal Bubble Cooling Pressure Blowers
For an internal bubble cooling (IBC) control system to function, there has to be forced movement of cold air into the bubble and hot air out of the bubble. This is done with high pressure blowers like the one shown.

For maximum possible air exchange rate the blowers must be properly sized based on the physical dimensions of the air flow passageways, the die diameter, and the maximum required volume. If the IBC blowers are not sized properly, loss in potential production rate will be the result.

Each of the elements (flow, pressure and horsepower) are described below. To provide optimum control of the flow rates, DRJ recommends the use of variable speed drives. Two added benefits of using variable speed drives include improved electrical efficiency and reduced noise levels when not running at maximum speed. The ABB version of the IBC system provided by DRJ uses a variable speed drive on blower drives to provide easy operator adjustment of the cooling flow rate and to allow automatic balancing.

Flow (Volume)
This is the first element that must be specified when sizing a blower. The flow required for internal cooling varies from extrusion line to extrusion line. In general, the larger the line the more flow is required. Many extrusion manufacturers use a simple rule of thumb to of 75-100 cubic feet per minute per inch of die diameter.

Pressure (Static)
After the flow value is derived, the static pressure required to produce that flow must be calculated. To do this properly, DRJ uses proprietary software that calculates the velocity pressure and friction losses through any style blown film die. In addition, the air temperature and elevation above seal level must also be considered to account for air density, which affects pressure and power requirements.

HorsePower
Once the flow and pressure are derived, the blower wheel diameter, width and horsepower are calculated. One of the most common misconceptions is that more horsepower means more flow. Without added pressure (which comes from a combination of wheel diameter and wheel speed), there is no additional flow. Also, there is a physical limit to the amount of air that can pass through a given area.



Internal Bubble Cooling Coils
Cooling coils are an important component in achieving the highest possible production rate from an internal bubble cooling (IBC) system. The inlet or supply air from the IBC supply blower passes through the cooling coil and is cooled to the temperature established by the chilled water supply. The chilled water supply comes from the plant chiller or an individual mini-chiller.

By chilling the inlet air temperature going to the IBC and air ring, an increase in production rate of 15-25% can be achieved when compared to using air that is at the ambient plant temperature. This benefit has added importance when the production occurs in climates where the ambient temperature varies a significant amount or where the summertime temperatures are very hot.

Sizing Cooling Coils
A coil that is too large will not maintain a constant temperature and a coil that is too small will not achieve the desired cooling temperature at all. Other specifications include the inlet and outlet sizes (flanged or unflanged) and support leg length. DRJ provides complementary sizing services with each IBC system we sell and we also can supply the cooling coil with the system.

Three-Way Valve
The optional 3-way valve provides an easy control of the desired chilled air temperature by reducing or increasing the chiller water flow though the coil.

Condensate Drip Pans
Integrated condensate drop pans ensure that condensation is collected and funneled to one point. This eliminates water intrusion problems when a cooling coil is installed above electrical equipment.



Sizing Cages
In the blown film extrusion process, the sizing cage (aka, sizing basket, calibration cage or calibration basket) is used to stabilize the blown film bubble directly over the die and air ring. Keeping the bubble stable over the die and air ring improves film quality by ensuring the air ring and internal bubble cooling effects are uniformly applied to the entire circumference of the bubble.

As production rate increases, and in particular, when internal bubble cooling is used, the sizing cage is a required feature. The higher production rates require more air flow on the bubble which results in bubble movement and sometimes complete instability. A six level cage, like the one shown here provides an excellent bubble stabilizer.

Sizing Cage Features
By necessity a sizing cage must come into contact with the blown film bubble in order to stabilize the material. Depending on the film properties, different styles of contact surfaces can be specified. This and a variety of other features all need to be specified when a cage is purchased.

Installation Guidelines
The key element regarding installation of a sizing cage is the height of the cage above the blown film die and the proper alignment over the die. For sizing cages that do not have a vertical height adjustment, the height position is critical to proper operation of the line.

Improper cage alignment will cause gauge problems, which can lead to roll conformation problems.

List of Manufacturers
Sizing cages come in a variety of designs and costs. Cages are available primarily through blown film extrusion manufacturers. Although there are at least two independent



IS-IBC1 High Temperature Ducting and Hose
Rigid ducting should be used as much as possible in internal bubble cooling air flow systems, but there are portions of the system where only flexible ducting (hose) will do the job. The most common use of flex hose is to connect the distribution plenum to the pipes on the bottom of the die. However, not all flexible hoses will hold up when continually exposed to the heat that comes from the bottom of the die. The high temperature can quickly fatigue the hose causing significant leaks or even collapse. Some flexible hoses have a cloth inner lining, which over time, tends to be pulled away from the hose by the internal vacuum which results in a difficult to detect airflow obstruction.

DuctingDRJ has a solution to your flexible duct hose requirements. A high strength hose capable of handling temperatures up to 500°F. This is an application proven hose is excellent for connecting the IBC exhaust and supply plenums to the die. The hoses that connect directly to the die come in ¾" to 3 ½" ID and compress a maximum of 25% of standard length. The main ducting sizes start at 4" ID and up and compress 50% of standard length.



Internal Bubble Cooling Diagnostic Tools
Handheld Setup Unit

The handheld IBC Setup Unit (ISU) is the latest diagnostics tool developed by D. R. Joseph, Inc. for allowing direct access to the IS-IBC1® Internal Bubble Cooling Systems and the new digital sensors. Lightweight, compact, and easy-to-use, the ISU is designed for easy access to the IS-IBC1® system for calibration, storing and retrieving parameter settings, diagnostics, and monitoring the process. It reduces the time required to setup and diagnose the IBC system by stepping the user through the common tasks. The ISU is especially useful for maintaining existing IS-IBC1® systems and storing recipes for lines with multiple dies and products.
Features when connected to:
IS-IBC1 System
  • Download and Upload functions allow quick transfer of any setup. Up to 10 setups can be saved.
  • Fast Find function quickly identifies what setup is running on the system and shows any changes that may have occurred.
  • System Monitor functions allow easy review of all inputs and outputs to the system.
  • Valve Calibration Tutor ensures the valve is calibrated properly.
  • Parameter Management allows only valid changes to any parameter.
  • Factory Defaults allows quick restoration of any IBC system to original factory settings.
 PP4 Digital Sensor System
  • Quick Search finds all sensors on the PP4 network. Note: digital sensors not on the PP4 network can be temporarily added to complete testing requirements.
  • Sensor Monitor shows internal sensor operation including signal strength, range, output status and temperature.
  • Verify function ensures all internal settings are valid.
  • Sensor Reset function restores the sensor to the original factory settings ensuring proper operation after any non-fatal fault.
Specifications

The unit is powered by the connected system, so there are no batteries to maintain. Power supply is 5 volts DC. The unit is also supplied with three levels of security to allow managers to define what features and parameters the user can access. It also is provided with language text in English, French, German, Italian and Spanish. Optionally, the unit can be interfaced with the IBM PC and Microsoft Windows based IBCViewer program. This D. R. Joseph program supports system setup management on your Windows based PC using a database.




Upgrade Corner
New High Speed Proportional Valve Improves Operation

Low melt strength materials require very fast control response time to maintain stability, particularly during startup and order changes. The new PA340 proportional valve has been recently introduced as the next generation proportional valve. Customers who have tested the valve have found an improvement in layflat control, and the ability to increase production rate.

The new proportional valve is different from the familiar cylindrical valves that have been used on IS-IBC1 systems for the past 14 years. The new valve is smaller, 30% faster, eliminates the 20 micron inlet filter, is quieter, cooler, and has three times the service life of our previous valves.




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