The KALIBRO is DOTECO's automatic calibration cage control system — a closed-loop controller that replaces manual cage adjustment on blown film extrusion lines. Ultrasonic sensors continuously measure bubble diameter and the gap between bubble and cage, then the controller regulates cage opening and height to hold the target lay-flat width throughout the production run.

How does KALIBRO automatically control the calibration cage?

Ultrasonic sensors mounted on the cage measure the actual bubble diameter after the frost line. The controller compares this against the target lay-flat width and adjusts cage opening via motorized actuators. It also regulates bubble inflation and deflation to maintain the correct gap between the film bubble and cage surfaces — preventing contact that would mar the film.

How does the system handle frequent size changes?

KALIBRO enables on-the-fly lay-flat width changes without stopping the extrusion line. The operator enters the new target width on the 5.7″ touch screen, and the controller automatically repositions the cage and adjusts internal bubble pressure to the new dimension. This reduces start-up scrap and changeover time compared to manual adjustment — especially valuable in operations producing multiple film widths per shift.

What quality data does KALIBRO provide?

The system logs process data — actual lay-flat width, cage position, and alarms — for statistical reporting and production lot validation. Communication via OPC UA, Modbus TCP/IP, or ProfiNet delivers this data to supervisory and MES systems, supporting the traceability requirements of ISO 9001 and food-contact film production.