RollTagger - Tracking Defects Automatically

Key Features for Roll Tracking

Removes requirement for inserting tags or marking the edge of your product

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Rewind & Unwind Modes

Rewind mode generates a map, measuring diameter and thickness. Unwind mode uses the map to boost productivity at the next process.

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Mapping Rolls

Real-time mapping with graphical display showing all key events such as defects and splices. Timestamp, linear offset, wind location and radial offset all latched.

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Job Management

Intelligent queue system for roll ID and map input, output, and backlog management. FIFO ordering with optional MES/ERP integration.

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Process-to-Process Transfer

Automated roll handoff between stations with complete data integrity and lineage tracking. Each station runs standalone but automatically seeks peers for roll handoff.

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Unwind Verification

Automated wind separation verification to identify positional anomalies such as material cuts or sagging. Compare actual vs expected positions with deviation alerts.

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Machine Interfaces

Input/Output to interface with commercial vision systems, unwinder splice detection and automated turret rewinders. System can be configured to operate automatically with no operator input required.

RollTagger supports standard industrial class controllers

Easy to install, deploy on multiple lines due to low cost of ownership and local supply.

Revolution Pi Connect industrial computer

Industrial Controllers

Industrial-grade edge computing platform for reliable roll tracking

Precision Encoders

High-precision linear and rotary encoders for absolute position tracking with sub-millimeter accuracy

Standard Industrial Controls

Use standard machine interfaces with RollTagger such as AB or Siemens

Frequently Asked Questions

Everything you need to know about RollTagger

RollTagger replaces the need to put physical tags in your roll
Tags can still be used and marked in the roll map
Wind number, radial offset from core, and linear displacement are all stored
RollTagger works with vision systems and other online measurement solutions to mark waste
Exact location stored - no physical flag needed

Uses only commerically off-the-shelf hardware
Software can run on standard PLCs, industrial microcontrollers and industrial PCs.
Interfaces with standard encoders and sensors. Preferred interface is RS485 Modbus.

Rewind Mode:

Used when creating new rolls from raw material
Records all encoder data, geometry calculations, and quality events
Position counts up from 0
Operators can tag defects, splices, and quality checks in real-time

Unwind Mode:

Used when processing existing rolls created elsewhere
Plays back events from the source rewind
Can control machine through supported industrial interfaces
Position counts down from target length to 0
System checks for material removal using automated wind verification

Rolls transferred between stations via factory local network
Each roll file contains complete session data: metadata, events, measurements, and lineage
Automated network transfers are supported using handoff triggers
Manual file-based handoff can be used using the export feature

RollTagger uses a three-queue architecture:

Input Queue: Rolls awaiting processing (FIFO order)
Output Queue: Completed rolls pending export or transfer
Backlog: Historical archive with configurable retention (default: 90 days)

All queue operations use atomic SQL to prevent race conditions and guarantee FIFO ordering.

Automated quality check at every 10-wind milestone during unwind
Compares actual position to expected position from source rewind
Calculates deviation in meters and percentage
Status indicators: OK (within tolerance), Warning (minor deviation), Critical (exceeds threshold)
Real-time alerts are sent to the operator

Each roll event causes the real-time latching of rewinder rpm, radial position, and number of winds
System also measures inter-wind linear displacement
When using dual encoders the system will measure diameter and thickness of the material

Designed for offline-first operation
All data stored locally in SQLite databases on each device
Network connectivity only needed for device-to-device transfers when enabled
Operates independently without cloud dependency

Licensed by end user or reseller
Perpetual or subscription solutions available
Hardware purchased and installed by end user or OEM
RollTagger software can be installed as a service remotely

Software Solution

Explore the RollTagger interface and discover key features that streamline your roll tracking operations

Comprehensive Roll Tracking Dashboard

Real-time monitoring of roll operations with live metrics, visual roll mapping, and proactive event management for complete production visibility.

Live operational metrics: length, speed, diameter, rotations, and material thickness
Visual roll map with event markers and upcoming alerts for proactive management
Complete event history log with timestamps, positions, types, and severity levels

Roll Map & Event Tracking

Visual timeline representation of roll progress with precise event positioning, buffered event queues, and detailed event history for quality control.

Horizontal roll map scaled from 0m to current length with colored event markers (defects, splices, checkpoints)
Buffered events queue for managing pending events before they're processed
Detailed event history table with timestamp, position, rotations, type, severity, and notes

Real-Time Metrics & Roll Visualization

Monitor critical roll parameters with instant updates and visual representation of roll geometry, enabling precise control and decision-making.

Six key metrics dashboard: current length, speed, diameter, rotations, material thickness, and event count
Interactive roll map visualization with length scale and color-coded event markers
Progress tracking showing current position versus total length for accurate monitoring

Queue Management & Roll Controls

Streamlined interface for managing roll operations with quick access to essential functions and real-time queue status monitoring.

Queue status display showing input/output/buffer counts (I/O/B) for instant visibility
Quick action buttons: New Roll, Material Adjustment, Tag Event, and station selection
Roll identification and editing capabilities with intuitive clipboard and pencil icons

Output Queue & Roll Transfer

Manage completed rolls with automated transfer capabilities, device assignment, and seamless handoff between production stations.

Current session monitoring with active roll processing details and read-only status
Output queue management for completed rolls ready for transfer or archiving
Device assignment and release functionality for automated roll handoff between processes

Map waste on the rewind. Remove it on the unwind.