RFID Strategy: How to Plan & Build a Scalable RFID System

If you’re building your first RFID system or looking to scale an existing one across multiple sites, our recent webinar with Zebra Technologies offered valuable insights to help guide the process. During this 60-minute session, attendees learned how to plan, grow, and future-proof their RFID infrastructure - exploring everything from simple handheld setups to enterprise-grade automated platforms.

Regardless of industry, environment, or RFID application, the session provided practical guidance on choosing the right components and avoiding common (and costly) pitfalls. Designed for all experience levels, the webinar brought teams up to speed quickly on what it takes to build a successful RFID system.

Key Topics Discussed

• A breakdown of basic, intermediate, and advanced RFID system components
• How to align your use case with the appropriate system architecture
• Strategies to scale from handheld RFID readers to fully automated solutions
• How Zebra’s RFID ecosystem enables scalability, automation, and measurable ROI
• Use of RFID systems in environments such as warehousing, retail, and manufacturing

Webinar Polls

Poll #1 What would you say your level of knowledge/expertise on RFID/IoT Is?

Brand New: 7% | Still Learning: 36% | Somewhat Knowledgeable: 37% | Very Knowledgeable: 20%

Poll #2 What is your primary RFID application?

Access Control: 3% | Asset Tracking: 36% | Identification/Authentication: 7% | Inventory Management: 41% | Other: 13%

Poll #3 Do you currently have an RFID system deployed/in use?

Yes, I do: 40% | Currently in the process: 19% | No - but I plan to in the future: 30% | No, just learning: 11%

Poll #4 Do you feel like you learned more in this webinar about RFID systems and how to build for scalability?

Yes, I did: 50% | Somewhat: 37% | I still have some questions: 13%

Webinar Q&A

We will be adding all of the questions and the relevant answers to this article as the answers are received. If you do not see your question/answer, or want to see these as they posted, bookmark this page or continue to check back! Additionally, all questions will be answered via email, so continue to check your inboxes if you submitted a question during the live webinar.

Question: We’ve been using ISO 18000-6C UHF RFID tags for several years. What would RAIN RFID do for us?

Answer: If you’re already using ISO 18000-6C UHF RFID tags, you’re already using RAIN RFID technology - you just may not have called it that. The term RAIN RFID was created by the RAIN Alliance, an industry group that promotes the adoption and awareness of this specific UHF RFID standard.

Think of it like Wi-Fi: most people don’t refer to the technical IEEE standard number - they just call it Wi-Fi. Similarly, RAIN RFID is a more accessible and recognizable way to refer to ISO 18000-6C technology. The goal is to simplify the conversation and help drive broader understanding and adoption across industries.

• • •

Question: What should we consider when using RFID to track metal piping?

Answer: Tracking metal items with RFID comes with unique challenges, primarily because metal can interfere with tag performance. Here are some key considerations:

• Use the right tags: Standard RFID tags won’t perform well on metal. Use tags designed specifically for metal surfaces, like the Silverline Blade II, a popular on-metal label option.
• Think about durability: If the goal is short-term tracking, such as verifying delivery to a job site, a lower-cost option like a metal-mount label, hang tag, or flag tag may work. For long-term tracking tied to inspection records or building code compliance, choose a rugged, permanent tag.
• Plan your read points: Optimize where antennas are placed to ensure consistent read performance, especially in environments with stacked or bundled pipes.
• Clarify tracking goals: Are you tracking individual pipes, bundles, or pallets? Your tagging strategy will differ depending on the level of granularity required.

Each use case is different, so your approach should align with how and where the piping is being tracked, as well as how long that data needs to be retained.

• • •

Question: Are fixed RFID readers directional?

Answer: Fixed RFID readers themselves typically don’t include antennas, they’re like radios without speakers. The directionality comes from the antennas you connect to them.

Antennas are directional, meaning they read tags based on how and where they’re pointed. For example, an antenna facing left will primarily read tags to the left. By positioning multiple antennas at different angles or locations, you can infer directionality (such as whether an item is entering or leaving a dock door).

Good system design is essential here - professional installation and thoughtful antenna placement can significantly improve read accuracy and coverage. There’s a wide variety of antenna types (short-range, long-range, etc.), giving you the flexibility to tailor setups to your workflow.

• • •

Question: How do retailers typically ingest supplier RFID tag data before delivery?

Answer: Most retailers rely on the GS1 standard to ensure consistency and data integrity when receiving RFID-tagged inventory from suppliers. GS1 provides a common encoding standard for tag data, making it easier to integrate information across systems.

Key considerations include:

• Ensuring your suppliers follow GS1 encoding guidelines
• Verifying that the printed data on the tags matches the encoded data
• Using GS1’s data sharing interfaces and tools to streamline communication

Retailers who don’t yet have suppliers tagging items can take control by printing and encoding tags internally, either at distribution centers or in-store.

Additionally, Auburn University’s RFID Lab is a leading resource for best practices, ROI guidance, and retail-focused RFID research. Their work has helped set industry-wide standards and is supported by major players like Walmart, UPS, and FedEx. If you’re new to RFID in retail, exploring Auburn’s resources is a great place to start.

• • •

Question: Can you install an RFID reader in a delivery truck?

Answer: Absolutely. RFID readers can be installed in delivery trucks, and this mobile setup opens the door to a wide range of use cases.

For example, Zebra’s FXR90 fixed reader is designed specifically for rugged environments like delivery vehicles. It’s 5G-enabled and available in multiple configurations, including models that support external antennas. This makes it ideal for tracking inventory inside the truck in real time.

However, it doesn’t have to start with a fixed reader. Even a handheld RFID reader can empower drivers to check truck inventory before and after each job. This is especially useful for field service teams who carry parts or equipment, as it helps ensure technicians have what they need and haven’t misplaced or misused assets.

Mobile RFID is also being used in garbage trucks, trailers for vaccine or food shipments, and other logistics scenarios where traceability and accountability are critical.

• • •

Question: Are there any generic software options available for basic RFID inventory management?

Answer: Yes - Avancir is a configurable RFID software platform designed to support a wide range of applications, including inventory management.

At a basic level, Avancir lets you associate item data with RFID tags and manage it in a standalone application. As your needs evolve, the software can scale with you - offering integration with backend systems and providing real-time insights that support smarter business decisions.

It’s a flexible solution that works well whether you’re just starting out or scaling to more complex RFID environments.

• • •

Question: We’re trying to add automatic RFID scanning at our dock doors to replace manual scanning. Should we use transition portals or fixed readers with antennas?

Answer: It depends on your specific use case, but both options can be effective depending on the volume and complexity of what you’re tracking.

If you’re dealing with a high tag population or need precise control over what’s coming in and out, a transition portal (a more structured setup with multiple antennas and shielding) might be the right fit. For lower tag volumes or simpler use cases, fixed readers with panel antennas may offer sufficient coverage at a lower cost.

Key considerations include:

• Tag population: Are you scanning a few items or dozens at a time?
• Read zone control: Do you need to avoid reading adjacent items or nearby dock doors?
• Scalability: Will your setup need to handle more items or different product types in the future?

Because every dock door environment is different, a site survey is highly recommended. At Atlas RFID, we offer on-site feasibility analysis, bringing hardware for real-world testing and providing a detailed deployment plan tailored to your environment. This ensures your RFID system works not just today, but as your needs grow over time.

• • •

Question: Are there 5G-enabled RFID tags that can triangulate location using cellular towers?

Answer: While there are prototype and niche solutions that use cellular connectivity - often referred to as 5G-enabled smart labels - they’re not yet widely adopted for most use cases. These tags typically include a battery (such as a printed or coin cell battery) and cost significantly more than standard RFID tags.

These high-cost, high-tech solutions are generally reserved for extremely critical or high-value assets, like organ shipments or sensitive pharmaceuticals, where real-time tracking is essential.

For most applications, there are simpler and more cost-effective alternatives. For example, some companies pair standard RFID reads with GPS data, capturing the location at the time the RFID tag is read. This hybrid approach offers valuable location tracking without the complexity or expense of cellular-enabled tags.

Bottom line: 5G tag technology exists, but unless your use case demands it, traditional RFID combined with GPS or other system integrations is often the better path.

• • •

Question: We want to track cattle across multiple farms. What RFID tags work best, and can they help monitor details like size, health, or weight?

Answer: Traditionally, livestock tracking has relied on low-frequency (LF) RFID tags—typically operating at 125 kHz. These tags are well-established in the agricultural industry, offering reliable animal identification. While LF isn’t a focus for Zebra Technologies, it’s a mature and proven solution widely used for cattle tracking.

That said, UHF (RAIN RFID) solutions are starting to emerge in livestock environments. Some farms are exploring UHF tags to gain extended read ranges and faster data capture. However, tagging animals with UHF is more complex and less common - so it’s best suited for specialized use cases or when there’s a strong reason to move beyond LF systems.

As for tracking health metrics like size, weight, or condition, RFID alone doesn’t measure those attributes - but it can be used to associate an animal’s unique ID with external systems that record such data. For example, RFID can trigger data collection at feeding stations, weight scales, or health checkpoints, creating a digital record for each animal over time.

If you’re interested in exploring UHF livestock solutions, contact us for follow up after the webinar and we can share examples from current clients using this approach.

• • •