Originally Posted By: nonchai
Another thing - bearing in mind the amount of crackles - and now I understand there's a "helper" BIAB app ( Band IN A Box Engine ) running behind the scenes - is the plugin streamingaudio from BIAB Engine or directly (with time-stretching if needed ) from the rendered audio for each track off-disk?

I'd understand why there's so much crackle if there's interprocess messaging etc going on between plugin and BIAB Engine each time an audio block has to be fetched. Although apps like Vienna Ensemble pro do this all the time with much more workload on my machine at the same buffer size so ought not to be any issue.
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Nothing is streamed from the BBW4.app the files have already been generated into the local folder.
What you can try is up-sample the existing 16bit 44100 files to 48000 and the bit depth your DAW is set to in the Saved Files folder then try sync playback and see if you get the crackling.
Just keep the original file names.
A simple way you could use a free tool like MediaHuman Audio Converter.