RollTagger builds a digital map of every roll as it winds — recording defects, splices and quality events at precise positions. On the unwind, that map drives automated waste removal. No physical tags. No manual watching.
Live demos run in your desktop browser — no sign-up or hardware required
Your path to live roll tracking
Tell us about your process — line speed, defect sources, number of lines. We map the solution to your setup at no cost.
Book a CallOrder the Revolution Pi, encoders, and I/O modules sized for your installation. Delivered ready to mount.
View HardwareInstall hardware, configure encoders and I/O, calibrate against known measurements, and validate with a test run.
See the StepsStart mapping rolls on the rewind. The system removes waste automatically on the unwind from the first roll.
RollTagger is a self-contained system — hardware, software and networking are all purpose-built for the plant floor. There is no cloud account, no IT infrastructure and no internet required during production.
One Revolution Pi Connect 4 per production line, mounted at the machine. Runs the full RollTagger stack locally — no server room needed.
A linear encoder measures material length; a rotary encoder tracks core rotation. Together they give real-time diameter, thickness, speed and precise position.
The UI runs in any modern browser on your network — panel PC, industrial touchscreen, or operator tablet. No software to install on client devices.
Digital inputs receive defect signals from vision systems and splice detectors. Digital outputs command the machine to stop, jog, or signal at tagged events.
Each device on the plant network can discover and transfer rolls to any other RollTagger device. A rewinder automatically pushes its completed roll map to the next process.
All data is stored locally in SQLite. Export to CSV or JSON for analysis. REST API and optional MES/ERP integration for work order import and reporting.
RollTagger is designed to go from unboxing to live production in a single shift. Follow these steps to configure, connect, and start tracking.
Before installing anything, identify the key points in your production line. Understand where defects are detected, where rolls are rewound, and where they are unwound. This determines how many devices you need and where machine I/O is connected.
Mount the Revolution Pi at the machine, wire the linear encoder to the nip roller or measuring wheel, and connect the rotary encoder to the rewind core shaft. Connect digital inputs from your vision system or splice detector.
Set the device to Rewind, Unwind, or Full mode via the settings panel. Enter your encoder resolution, core diameter, and material path buffer distance. Run a calibration wind to verify diameter and position accuracy against known measurements.
Place each Revolution Pi on your plant LAN. Open the Devices panel on any unit to discover others on the network and pair them. Once paired, completed roll maps transfer automatically from the rewind output queue to the unwind input queue.
Mount a second Revolution Pi at the unwinder. Wire encoders in the same way as the rewind. Connect digital outputs to your machine control system — these outputs trigger stop, jog, or alert signals when each tagged event is reached during unwind.
Start a rewind session, wind the roll, and let RollTagger map it in real time. When the roll is complete, transfer it to the output queue. It moves automatically to the unwind. Load the roll at the unwinder, start the session, and the system takes over.
From the moment a new session starts at the rewind to the point the roll is consumed at the unwind, every step is tracked and every transition is verified.
Encoders map material length, diameter and events in real time as the roll winds.
Session is closed, roll map is validated and packaged as a .rtag file.
Roll is placed in the rewind output queue and transferred to the paired unwind device.
Unwind device receives the .rtag file and places it in its input queue, ready to load.
Rewind map plays back against the live encoder feed. Events trigger machine actions automatically.
Session closes, roll moves to backlog. Full lineage record retained for 90 days.
Every installation is different. Tell us about your process — line speed, encoder mounting, vision system integration, and how many lines you want to track. We'll map out exactly what you need at no cost.