US Patent 8001745 Systems for monitoring and controlling usage of materials

Material usage tracking systems for monitoring and optimizing usage of stretch film on a stretch wrapping machine is provided. A system includes a rotary encoder collar securable to a pre-stretch roller of a stretch wrapping machine and a proximity sensor securable proximate to the rotary encoder collar. Upon installation, the proximity sensor measures the revolutions of the pre-stretch roller when the stretch wrapping machine is wrapping a product or pallet. The system also includes a controller in communication with the proximity sensor. The controller converts the revolutions of the pre-stretch roller to measurements of the amount of stretch film pulled off a film roll in the stretch wrapping machine based on data received from the proximity sensor. Different uses for the data collected by the material usage tracking system and different ways of presentation of the data are also provided.