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• 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 commercially off-the-shelf hardware
• Software runs on the RevPi Connect 4 industrial controller (preferred), standard PLCs, or industrial PCs
• Interfaces with standard encoders via RS485 Modbus — preferred encoder is the BRT absolute rotary series

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

• Controllers cluster using ISA 95 hierarchy and automatically discover each other on the network
• Each process runs in rewind mode (recording) or unwind mode (reading) depending on position in production flow
• As rolls move from print → laminate → coat → slit, defects accumulate at each stage
• Virtual unwinding with path length delay ensures events align properly when transferred between processes
• Print defects carry forward to laminating, then print + laminate defects carry forward to coating
• Material waste percentage is calculated at each unwind stage, maintaining complete roll lineage
• Example: 3 rewind stations (print, laminate, coat) feeding 1 unwind station (slitter) with full defect visibility

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 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