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Splice detection with 1DC 480 sensor at 1000 fpm

Splice Detection

Splice detection identifies tape splices, overlaps, and butt joints as they move through converting, printing, and coating machinery. Roll-2-Roll Technologies provides sensors that detect splices automatically—including transparent splices on clear webs—preventing splice-related damage to downstream equipment and ensuring splice-free product delivery to customers. Unlike standard photo-eyes that struggle with clear materials, our sensors detect the subtle density and thickness changes that indicate a splice.

The Challenge: Undetected Splices Cause Damage and Quality Failures

Splices are necessary to join rolls during production, but they create significant problems:

  • Equipment Damage: Splices entering printing presses, laminators, or coating dies cause damage to expensive plates, dies, and doctor blades.
  • Customer Rejections: Splices in finished product packaging create visual defects and structural weak points that fail quality inspections.
  • Clear-on-Clear Detection Failure: Traditional photo-eyes cannot detect transparent splice tape on clear films—the most common scenario in flexible packaging.
  • Manual Flagging Waste: Operators manually flag splices with colored tape, but flags are often missed or fall off, allowing splices to pass undetected.

The Solution: Automated Splice Detection with Material Intelligence

Roll-2-Roll splice detection sensors analyze the full width of the web, detecting density changes, thickness variations, and edge irregularities that indicate a splice.

How It Works

  1. Full-Width Scanning: The sensor captures a 1D image across the entire web width
  2. Density Analysis: Advanced algorithms detect the subtle density change where splice tape overlaps the web
  3. Edge Irregularity Detection: Butt splices create edge disruptions that the sensor identifies instantly
  4. Automatic Flagging: When a splice is detected, the system triggers reject mechanisms or marks the location for removal

Key Advantage: Detects clear-on-clear splices that defeat standard photo-eyes. Works on opaque, transparent, and porous materials without calibration.

Key Benefits

  • Prevent Equipment Damage: Stop the line before splices enter expensive downstream equipment
  • Eliminate Customer Rejections: Ensure splice-free product delivery by rejecting spliced sections automatically
  • Detect All Splice Types: Identifies tape splices, butt splices, and hidden double-sided tape
  • Works on Clear Films: Detects transparent splice tape on transparent webs—the "Holy Grail" of splice detection
  • No Manual Flagging: Automated detection eliminates reliance on operators manually flagging splices

Applications by Industry

  • Flexible Packaging Converting — Prevent splices from entering pouch making equipment. Protect printing plates and coating dies.
  • Label Printing — Detect splices before they damage expensive flexo plates or digital print heads.
  • Battery Manufacturing — Remove spliced electrode sections that create cell performance inconsistencies.
  • Medical & Pharma — Ensure splice-free packaging for sterile medical devices and pharmaceutical products.
  • Film Extrusion — Monitor rewind stations to detect splices in incoming rolls before they enter the extruder.

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