Product
RollTagger
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. The system runs entirely on-premise using industrial Revolution Pi controllers with dual encoder inputs for sub-millimetre position precision.
Key capabilities
Rewind mapping
As material winds onto the roll, RollTagger records every millimetre. Dual encoder data calculates real-time diameter, thickness, speed, and rotation count — building a precise digital twin of the roll.
Automated unwind waste removal
On the unwind, RollTagger loads the rewind map and plays it back against the live encoder feed. Events trigger configurable machine actions — stop, jog, or skip — eliminating manual watching.
Multi-process defect tracking
Track defects through multiple processes and remove at the final operation such as slitting. Full roll lineage and parent-child traceability across every production station.
Wind verification
Automatic quality checks at every 10-wind milestone comparing actual to expected position from the source rewind map. Deviation alerts for positional anomalies.
Queue management
Three-queue architecture (input, output, backlog) for multi-station workflows. Rolls transfer automatically between devices via .rtag file handoffs over the local network.
Machine interfaces and MES integration
Digital I/O to interface with vision systems, splice detectors, and turret rewinders. REST API and batch CSV import for MES/ERP integration.
Specifications
Typical applications
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Our engineering team can assess your process and recommend the right configuration for your specific application.