Not All Internal Bubble Cooling Systems Are Built for Today’s Film Lines
When maximizing blown film performance, the Internal Bubble Cooling (IBC) system is a critical investment — and not all systems are up to the task. Lower-tier solutions may promise production gains, but often fail to deliver on width tolerance, bubble stability, line speed, and ease of use across different materials and operators.
The 4th Generation IBC System from D.R. Joseph is engineered to outperform — with real-world production gains of 15–40% when adding IBC to a non-IBC line, and 8–15% higher output compared to other IBC systems. These results are driven by proprietary control algorithms, patented dual sensor technologies, and automation that eliminates manual calibration and tuning.
And beyond speed or stability, you’ll benefit from:
- Operator-boosting technology that helps new users perform like veterans
- Widest material compatibility in the industry — from 0.3 mil to 100 mil, HDPE to high-performance exotics
- Remote service tools that solve problems in minutes, not hours
- Rugged, globally proven reliability with modular designs and fail-safe architecture
Whether it’s a monolayer lab line or an 11-layer high-output system, DRJ’s IBC platform is built to grow with your goals.
Expect More From Your Internal Bubble Cooling System
- Balances flow rate of inlet/outlet blowers
- Maintains balance as process conditions change
- Reports airflow blocks/leaks
Value: Less operator intervention, consistent SOP
- “Set it and forget it” size changes and start-up
- Measured via bubble diameter for faster response
- Configurable layflat alarms
Value: Reduce waste of your most valuable resource: resin. Also reduce out of spec material
- Positions cage diameter to optimally achieve target layflat size
- Less operator intervention at start-up and quicker size changes to reduce scrap
Value: Expedites size changes, consistent SOP
Automatic Valve Calibration (patented)
- Automatically calibrates airflow control valve to any die or restrictions in air path
- Includes comprehensive airflow diagnostics to expedite troubleshooting
Value: Keeps system running in “like new” operation
Automatic Layflat Calibration (patented)
- Automatically calibrates width at the winder, compensating for stretch, shrinkage, & other process variations.
- Infrared sensors near winder measure final film width & adjust the control system in real time
Value: Precision automation ensures final layflat width accuracy —reducing scrap, eliminating manual calibration, and delivering perfectly on-spec rolls every time
Want Even More From Your Internal Bubble Cooling System?
Push Performance Further with Optional Enhancement
The D.R. Joseph 4th Generation IBC platform is designed to scale — offering a suite of advanced options that extend automation, improve quality control, and streamline operator tasks.
Automatic Layflat Calibration (Patented)
Stop using tape to check layflat. This system automatically calibrates the IBC’s layflat reading to match the actual finished roll width measured at the winder. It accounts for stretch, shrinkage, and draw down the tower, ensuring width accuracy, system safety, and operator confidence.
Neck Height Control
For high-stalk bubbles, neck height consistency is key to maintaining dart impact strength. A dedicated sensor measures bubble flare, and the system adjusts air ring speed or temperature to hold neck height within specification — improving film toughness and process repeatability.
Cage Height Management
Operators can predefine cage height positions for specific jobs, setups, or maintenance. At runtime, simply tap a button to move the cage to its programmed height — no manual positioning or guesswork required.
Data Logger with FTP Export
Continuously records all IBC process data and exports it in .csv format via built-in FTP. View data in DRJ’s LogViewer or import to Excel for Production analysis, SOP verification, Quality audits and Root cause investigations
WinViewer Remote Interface
Add a second HMI interface on a PC workstation to remotely monitor and control the IBC system. This full HMI mirror provides operational flexibility for control rooms, shift leads, or remote support scenarios.
Geo / Ag Internal Bubble Cooling Control
Geo & Ag Film Cooling Demands a Purpose-Built Solution
Standard Internal Bubble Cooling systems fall short when it comes to large-bubble geomembrane and agricultural film extrusion. These processes involve unique dynamics — thicker gauges, slower cooling, and broader layflat ranges — that require more than just scaled-up components.
That’s why D.R. Joseph developed the Geo/Ag IBC Control System — a specialized solution engineered from the ground up for large-format film cooling. Unlike generic systems, it employs:
- A custom control algorithm optimized for large bubble dynamics
- Fixed-position sensor arrays above the air ring and frost line for dual-stage measurement
- Oversized valves and flow components for high-volume air delivery
- Real-time tuning of the lower sensor set to maintain exact layflat as thickness and materials change
The system continuously adjusts the sensor-to-bubble distance to maintain target width as processing conditions shift — a capability unmatched in standard IBC platforms. Layflat control is refined by a second set of sensors above the frost line, giving the system a complete profile of bubble shape and stability.
All standard DRJ IBC system features are included, such as:
- Automated startup
- Layflat width control
- Statistical reporting (2σ/3σ)
- Bubble break detection
Supported BUR range: 0.90 to 1.50
This isn’t a modified blown film controller — it’s a dedicated solution for the unique challenges of Geo/Ag film production.
From 3rd to 4th Generation IBC Advancements
Over 35 Years of IBC Innovation — and Still Advancing For more than three decades, D.R. Joseph has continually evolved its Internal Bubble Cooling (IBC) systems through four generations of control innovation, automation, and field experience. Many of the improvements introduced in our 3rd Generation platform remain foundational today — while our 4th Generation system builds significantly on that legacy with expanded processing power, cybersecurity, and intelligent automation.
Key 3rd Generation Enhancements (Still Included in 4G)
An 8” color touchscreen introduced in Gen 3 brings all controls — IBC, blowers, cage, and layflat — into a single, streamlined interface. This UI remains standard in Gen 4, now with expanded multilingual and help features.
A high-visibility xenon lamp flashes based on fault or configuration state — whether manual mode is mistakenly active or a bubble break is detected. Can be configured with audio.
More than 50% of service issues were traced to airflow path problems. The system now monitors and alerts for clogs, collapsed hoses, leaks, or dirty filters in real-time.
Automatically tunes airflow valves for any die size or restriction. Diagnostic tools assist with troubleshooting during setup or changeovers.
Setup guidance helps engineers and operators with key placement and tuning — such as layflat sensor position, blower ratio setup, or bubble break detector distance.
Systems from Gen 1 through Gen 3 are all supported with upgrade pathways. Existing hardware and training investments are protected.
3rd Gen introduced structured OEM integration paths and Auto Profile Control compatibility — carried forward and expanded in Gen 4.
What’s New in the 4th Generation?
Delivers 16× the processing capacity of Gen 3, with two dedicated cores for analog and digital signal handling — improving real-time responsiveness and bubble control stability.
Includes Active Directory integration, segmented Ethernet ports, and user-level access controls to meet modern plant cybersecurity standards.
Introduced in Gen 3, these sensors maintain control even during communication failures. In Gen 4, their performance is improved with dedicated signal processing processors — ensuring stable operation under variable plant conditions.
Optional Add-On Features for the 4G IBC System
The layflat calibration system ensures the measured width always reflects the true physical output — without operator tape measurements or manual data entry.
See ALC section below for more information!
Automatically positions cage arms (diameter) to optimally achieve
target layflat and maintain proper cage contact. Cage must be motorized with smooth diameter actuation.
The latest IBC system now integrates with the TDK-500 Insta Gauge air ring. When the two systems are paired, the IBC related touch screens are placed on the 19″ InstaGauge touch screen. When the IBC system detects a stable bubble state, InstaStart automatically starts the gauge scanner so that auto profile control can commence. Similarly, when an unstable bubble condition is detected by the IBC system, the scanner is retracted to protect the sensitive gauge head of the scanner.
Stores critical diagnostic data for later retrieval and analysis — allowing DRJ’s service team to reconstruct intermittent issues and resolve them faster.
Automatic Layflat Calibration (ALC)
Absolute Width Control Without Tape or Guesswork
The Automatic Layflat Calibration (ALC) option enhances the D.R. Joseph IBC System and Width Controller by providing closed-loop calibration based on the final film width at the winder — eliminating the need for manual measurement and improving long-term accuracy.
🎯 Why ALC Matters
As film travels down the tower from the primary nip to the winder, its width is affected by multiple dynamic variables, including:
- Web tension variations
- Polymer and resin characteristics
- Gauge and temperature shifts
- Ambient temperature and humidity
- Plant air pressure fluctuations
These factors can cause shrinkage or stretching in unpredictable ways. ALC solves this by continuously correcting for those effects — ensuring the layflat system’s internal measurement reflects the true final roll width.
⚙️ How ALC Works – Two Points of Measurement
⚙️ How ALC Works – Two Points of Measurement
- Primary Layflat Control (Point A):
Ultrasonic sensors positioned mid-tower (below the frost line) manage active layflat control by making quick adjustments to dampers and blower speeds. This corrects for air loss, pinhole leaks, internal thermal gain, and ambient temperature variation. - Final Calibration (Point B):
A secondary flat width measurement bar (FE-8) near the winder measures the actual film width on the core. The system uses this data to automatically calibrate the ultrasonic layflat system, closing the control loop and correcting for all stretch/shrink variables.
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✅ ALC Benefits
- No manual tape measurements — improves safety and eliminates entry errors
- Tightens layflat tolerances for high-specification jobs
- Speeds up job changes by eliminating manual calibration
- Reduces scrap during transitions and restarts
- Provides a true end-of-line quality control checkpoint
Whether you’re changing orders frequently or targeting tight customer specs, ALC ensures every roll hits the mark — consistently and automatically.
Consistency for High Stalk HDPE & MDPE (Optional)
Automatic Neck Height Control is an optional add-on for the D.R. Joseph IBC System that provides precise, automated regulation of neck height in HDPE and MDPE high stalk bubble applications — improving film consistency and boosting production confidence.
⚙️ How It Works
An ultrasonic sensor monitors the vertical distance to the flare at the bottom of the bubble — a key indicator of neck height. The system maintains this height to within ±0.25 inches (6 mm) by adjusting the air ring blower speed in real time.
This control loop relies on integrated feedback from:
- The Neck Height sensor
- The IBC layflat control sensors
Together, they provide coordinated control of both layflat width and vertical bubble profile during:
- Startup
- Hole recovery
- Normal production
Operator Confidence, Process Stability
When both width and neck height are automatically maintained, operators gain the confidence to:
- Increase extrusion speed
- Reduce out-of-spec scrap
- Stabilize startup quicker
- Avoid dart impact variability
This encourages better use of line capacity without risking film quality.
🔌 System Integration
Neck Height Control is designed to integrate with the DRJ IBC system’s automatic width control and connects to air ring blowers via:
- Standard serial communication
- Compatible with Yaskawa A1000, P1000, or V1000 inverters
✅ Benefits
- Consistent neck height = improved dart impact strength
- Reduced film property variation in HDPE/MDPE applications
- Better layflat control through IBC feedback coordination
- Increased line throughput with fewer process upsets
Sustainable Blown Film Investments Start with Width Control
Precision layflat control isn’t just good process engineering — it’s a direct path to measurable resin savings and waste reduction, two of the most impactful levers in sustainable blown film production.
Reduce Resin Consumption at the Source
In many plants — especially those without IBC or advanced width control — extra material is run intentionally wide to ensure target width after trimming. This results in:
- Unnecessary edge trim
- Excess resin consumption
- Material that may be difficult or impossible to reprocess (e.g., multilayer or barrier films)
DRJ’s IBC systems reduce trim and over-production by maintaining tighter layflat tolerance, which leads to significant annual savings.
Case Example:
For a 3 mil (75 micron) film, uncontrolled edge trim can exceed 13,225 lbs (6,000 kg) per year per line — all wasted material.
Width Control Supports Sustainability by:
- Eliminating or minimizing edge trim
- Reducing scrap at startup and job changeovers
- Avoiding returns or re-runs due to width deviations
- Enabling extruder auto-stop if a bubble break is detected — preventing die drool and cleanup waste
Making PCR Viable with Automation
Post-Consumer Recyclate (PCR) introduces variability in:
- Melt quality
- Contamination levels
- Material blend consistency
These factors make manual width control unreliable. DRJ’s automated width control and layflat calibration provide the stability needed to run PCR consistently — making sustainable resin strategies viable for high-spec film production.
Sustainability in blown film begins with control.
Whether you’re aiming to reduce virgin resin use, increase PCR content, or simply cut waste — automating layflat with DRJ’s IBC platform delivers clear, measurable results.
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