The printing and converting industry standard in defect marking and tracking


  • Applies Pre-printed, Individually Numbered Flags
  • Records the Location, Type, and Length of Defects
  • Creates Roll Maps with the Data Collected
  • Prints a Report or Uploads Roll Maps to a Plant LAN
  • Data Can be Used to Create Efficiency Reports

ScrapTracker is a system which creates a data file or “roll map” associated with each roll of material manufactured, processed or printed. The data file contains all the information about the locations and types of any defects within the roll. ScrapTracker uses the AF3 WebFlagger to apply flags with unique ID numbers. The flags are pre-printed with a unique number and a corresponding bar code. A flag can be triggered by an operator pushbutton or a signal from the machine. When a flag is signaled to be applied, the flag’s ID number is recorded along with the type of defect and its location within the roll. Six different types of defect can be logged. ScrapTracker creates a roll map for each roll produced in the form of a data file. This data file can be printed as a report or uploaded to plant LAN or any data storage device.

The roll report created can be used in the subsequent process to help identify the type of defect to be inspected and/or removed. If the downstream process is equipped with our RollCode system, the roll map data is used to automatically stop the machine at each flagged location. The data in the roll map can also be used to create custom reports for scrap. Reports such as total amounts of scrap, scrap by machine, shift, month, etc. can be generated. These reports allow a quality control department easy access to this valuable data used for process improvement and scrap reduction programs.

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Direct Losses

Rolls per shift (average)

Defects flagged per roll

Shifts per day

Shifts per weekend

Rolls per week

Flagged defects per week

Feet lost per defect by inaccurate flagging

Cost per foot (average)

Cost per week

Cost per year

Indirect Losses

Extra minutes spent per defect at rewinder/slitter due to inaccurate flagging

Rewinding/slitting cost per hour in dollars

Cost per week

Cost per year

Miscellaneous Losses

Yearly dollars lost due to returns/rework from unflagged defects getting to customers

Yearly dollars lost due to lost time accidents due to manual flagging

Total Potential Savings per Year Calculate