Advanced Label Replacement with Tagsurance® 3

In RFID tag production, one thing is certain: there are always tag rejections, and the yield is never 100%. Failures happen; everyone in the industry knows it and must be prepared for it. However, the end customers justifiably have requirements for the RFID tag batch deliveries. The requirements can define the minimum yield, maximum allowed number of consecutive failed tags, or total maximum number of failed tags in each roll of tags. 

To meet these requirements, the tag manufacturer may sometimes need to replace failed tags with new ones. This replacement can be done as a separate process in a reel-to-reel machine or directly in the manufacturing machine, such as a converting line, at a ‘doctoring’ station. Advanced quality control is needed to make this process efficient and reliable. With Tagsurance 3 version 4.3.0, released on September 29, 2025, we introduced new features that help label manufacturers make the replacement process easier and more reliable while meeting customer quality requirements.

Stop Signal for the Machine Based on Test Result

Based on the test results, Tagsurance 3 can now tell the machine to stop the lane when a replacement label is needed. When Tagsurance 3 is in charge of the lot management, manufacturers can implement the label replacement process on any machine that supports simple ‘slow down’ and ‘stop’ signals. This results in even more basic machines becoming compatible with advanced quality control workflows, as no built-in stopping logic is required. The user can define the result-based logic in Tagsurance 3.

Replacement Label TID Tracking: Keep Your Data Clean 

When tags are replaced, the original test results are no longer valid, and key statistics, such as yield, become inaccurate. For both the manufacturer and the end customer, it is essential that the reported results match the actual deliveries: the lot results must correspond precisely to the output tag reel.

With Tagsurance 3 integrated, the manufacturing process includes test stations both before and after the replacement location (the ‘doctoring’ station). As a standard feature, Tagsurance 3 enables the capturing and reporting of test results, data such as TID, and statistics as part of the lot results. The new improvement is that this same data can now also be captured for the replaced labels at the second test station. Lot management takes into account only the test station results after the replacement location, making the lot results accurate.

Together with the stop signal feature, Tagsurance 3 can now provide a complete solution for quality control and label replacement process, as well as accurate encoding and batch data results.

Read more about the Tagsurance 3 lot data exporting capabilities: https://voyantic.com/blog/posts/improved-lot-data-export-during-test-runs/