Leverage Digital Twinning and advanced analytics to eliminate manual tagging, optimize yield, and automate defect removal across your entire converting process.
Request a guided tour or self-service demo — we'll get you set up
Your path from pilot to measurable ROI
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 building Digital Twins on the rewind. Automated waste removal on the unwind from the first roll — with yield data flowing from day one.
Beyond machine-level precision — measurable returns across labor, margins, and customer trust.
Automate the unwind and remove the need for operators to manually watch rolls. Machines run faster when driven by software precision rather than human reaction times.
Yield analytics highlight exactly where material waste happens — by process stage, defect type, and supplier. Fix root causes instead of absorbing recurring losses.
Ensure 100% defect removal before shipping. Every roll carries a complete Digital Twin audit trail for confident quality assurance and claim resolution.
A complete Digital Twin platform — edge hardware, roll quality software, and plant-floor networking built for industrial converting. No cloud dependency, 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, defect sources, and how many lines you want to track. We'll map the business case and technical requirements at no cost.