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Industrial Barcode Printing for Manufacturers

10 mins

Hope Jones

Barcodes have come a long way since their adoption in the 1970’s. Originally created to streamline the checkout process; they are now the most useful tool for supply chain management.

They have played a huge role in the evolution of communication through technology and continue to aid the delivery of product information to manufacturers, retailers and consumers across the globe.

A shift in how manufacturers apply barcodes

The main responsibility of applying barcodes onto packaging and shipping material falls on manufacturers. And, recent advancements led by GS1 (Global Standards 1) in 2D barcoding has meant many industries are having to re-evaluate, how, when and where they need to print their codes.

Find out more about GS1 Sunrise 2027

Luckily, that’s what we specialise in, not the artsy, graphics and digital printing, but the more technical process of late-stage printing variable information and barcodes directly onto products.

To make the process that smidgen easier, we’ve created an in-depth guide on barcodes for professionals in operations, factories and warehouses who may not have had much to do with the process before.

Here’s what you can expect to cover:

What is a barcode?

What are benefits of barcodes for manufacturers?

Should I choose a 1D or 2D barcode?

What type of barcode suits my application?

Pre-printed vs. on-demand barcode printing

Industrial printers for on demand printing of barcodes

Different types of coding technology for printing barcodes

Considerations when printing barcodes on the production line

Benefits of printing variable barcodes away from the production line

Why should you work alongside a GS1 partner?

What is a barcode?

We’ll start with the basics.

1D Barcodes represent alphanumerical data in a machine-readable format, consisting of black vertical lines of differing widths, usually alongside a string of numbers.

In simple terms, a laser is scanned over the barcode, which detects the pattern of light being absorbed and reflected by the black and white lines.  This is then interpreted by the scanners that turn the pattern into human-readable data.

On the other hand, 2D barcodes contain information both horizontally and vertically, they are a graphic image that can be read using image scanners such as mobile phones.

Both are used across all industries and at every stage of the supply chain to deliver information on a product.

What are the benefits of barcodes for manufacturers?

Previously the main benefit of barcodes was their ability to reduce human error and increase efficiency in retail environments, whilst also assisting manufacturers in managing stock levels, product handling and order fulfilment.

However the introduction of 2D barcodes uncovered a whole range of benefits for manufacturers and businesses, which will only continue to improve with the introduction of more advanced GS1 barcodes.

Benefits of 2D barcodes:

Streamlines product recalls

Being able to track products and individual components from production to supermarket shelves, means much quicker and more efficient retrieval of goods in the instance of product recalls. It becomes easier to identify issues in particular batches, and then rectify this across the supply chain.

Improved traceability and serialisation

The pharmaceutical, cosmetics and medical industries, particularly benefit from unique identification of individual products. Items that are potentially harmful, open to misuse, or commonly counterfeited, need to be uniquely tracked to adhere with strict regulations.

In-depth data collection

The development of new barcodes as a result of the GS1 initiative will lead to more accurate data collection and reporting for manufacturers, particularly in areas such as consumer behaviour and production efficiency.

Advanced advertising and marketing

2D QR codes have been increasing in popularity over the last few years, sped up by the Covid-19 Pandemic. They create stronger, personalised connections between consumers and businesses, an example being the development of immersive marketing experiences using augmented reality barcodes.

Should I choose a 1D or 2D barcode?

The main difference between 1D and 2D barcodes is the amount of information stored within them. There is also a difference in how they are generated, implemented, scanned and tracked. So, you need to be able to fully differentiate the two and make that choice based on your specific requirements. Compare with the table below:

1D vs 2D barcodes - comparison tables

What type of barcode suits my application?

Now you know whether you would like to go down the route of 1D or 2D barcoding, you will need to decide what type of barcode will reflect your data in a format that is most relevant to your industry, application, product or packaging. There are a few key players that you need to know about but be sure to get in touch if you require more in-depth advice on specific barcodes.

1D Barcodes

EAN-13

A barcode for the unique identification of goods. Encoded with GTIN (Global trade item numbers.) Retailers use it for pricing and scanning at checkouts. Assists with the movement of goods across the supply chain and in warehouses.

EAN – 8

A more condensed version of the EAN-13 code that is used on products where there is little space for a barcode. It includes the country, manufacturer and product code.

Code 128

Alphanumeric or numeric-only barcode. Ideal for shipping labels as it is a variable length barcode that provides greater density of information than traditional barcodes. Perfect for inventory control and supply chain management. Commonly used in the healthcare and logistics industries.

UPC- A/E

Mainly used in the United States, these barcodes are often used on point-of-sale goods. Like EAN codes they also contain the GTIN (Global trade item numbers.) However, the main difference is their geographical usage and the amount of human readable information.

ITF barcode

ITF Barcodes

Often used on cases, pallets and products that aren’t sold in retail stores. They are 14-digit barcodes used to track and manage products in the supply chain. They can be printed directly onto cardboard.

2D Barcodes

QR Codes

These barcodes are heavily used by consumers to gain information about a product, promotion or specific marketing campaign. They generally contain lots of information such as a URL, images or videos. The codes can be scanned and read by smart phones making them ideal for POS packaging.

Data matrix Codes

Designed to store large amounts of information in a small area. Used primarily for medical, pharmaceutical, and electronic applications. It has a high level of fault tolerance.

GS1 Standards

GS1 Digital Link Barcodes

Next generation barcodes that have increased data capabilities which benefit businesses and consumers. The purpose is these 2D barcodes embedded with a digital link, can be scanned at both retail point of sale and across the rest of the supply chain, therefore communicating vital data and information to consumers.

Pre-printed vs. on-demand barcode printing – the effect of the Sunrise 2027 Initiative on manufacturers.

Traditionally linear barcodes have been pre-printed on primary packaging, as their sole purpose was to provide fixed data such as a GTIN code. Any variable information was applied separately by industrial coders on the production line.

The GS1 Sunrise initiative will deliver more in-depth information to consumers, and everyone across the supply chain in one “Digital link code”, with the aim to phase out the traditional barcode by 2027. As the global supply chain moves closer towards 2D codes that contain variable information, it will be necessary to print barcodes during the production process.

On-demand barcode printing is not a new phenomenon, however, has been isolated to pharmaceutical manufacturers who print serialised data matrix codes or when printing shipping information on outer cases.

Soon all industries will be required to print late-stage barcode information directly to their packaging. Which is why it is crucial manufacturers are in communication with industrial coding and marking companies who can assist them in the process of printing barcodes on demand.

Industrial printers for on-demand printing of barcodes

Industrial printers or coders, apply late-stage information directly to products and packaging. This includes 1D and 2D barcodes, batch numbers, date codes and even graphics or logos. The systems can either be integrated onto a production line or attached to a dedicated off-line system that both feeds and prints onto the packaging before it is filled.

Software is often included with the equipment, that means you can generate, implement, and print barcodes in one place. Certain print design softwares such as iDesign, allow you to generate GS1 standard barcodes.

Different types of coding technologies for printing barcodes

There are various technologies that are capable of printing barcodes onto packaging. Your choice of technology will depend on your application requirements.

Thermal Inkjet (TIJ) printing

Non-contact print technology that uses interchangeable ink cartridges.

High-resolution and maintenance-free, the compact units can be integrated into most manufacturing equipment.

Read more: Why choose Rotech as your thermal inkjet supplier?

Outer case printing

Non-contact printers that remove the need for a label and application system, reducing waste and saving costs on consumables.

In addition to variable and product information, the printers can apply high-quality barcodes directly onto outer cases and shipping boxes.

Thermal Transfer (TTO) printing

A contact print technology, ideal for large print areas, on flexible film, label stock and medical paper (Tyvek®).

Laser marking

An environmentally friendly non-contact technology, laser coders work by etching or vaporising the surface layer of the material, leaving an inerasable mark.

Continuous Inkjet printing

Non-contact print technology with very good adhesion to most packaging materials, meaning it’s ideal for high-speed production and printing on curved surfaces, i.e. the bottom of a can.

Considerations when printing barcodes on the production line

When choosing industrial coding and marking equipment for your production line, you must consider key factors to decide the most appropriate technology for your application requirements. Some questions you should ask yourself are:

  • Substrate to be printed onto – Is it a porous or non-porous surface?

Certain technologies have better ink adhesion on glossy surfaces.

  • Shape of the product – How far away does the printer need to be from the substrate?

A contact printer would not be suitable for a curved surface. Furthermore, printers vary in their ink throw distance, which will affect the technology you choose.

  • Budget – How much can I afford to spend on this printer, now and into the future?

Hidden costs such as maintenance, consumables and downtime can take you by surprise. The initial investment and the true cost of ownership need to be considered.

  • Print area – Is there enough space to print a legible barcode?

How much space is available to print the barcode and does it include the recommended “quiet zone”? What print height is required to suit the application?

  • Integration with existing equipment – What manufacturing equipment does the printer need to be installed onto?

Do you have existing equipment that you would like the printer to work alongside? If so, you must consider the space available, and at what angle the printer needs to be positioned. Alternatively, you may require an all-in-one coding system.

  • Speed of production line – How many metres per second does my machine run at?

Your chosen coder must be able to keep up with production to prevent downtime or delays caused by bottlenecks.

  • Production environment – Does the coder need to withstand harsh environments?

If you work within a dusty, damp, or wet working environment, you will need to consider the IP rating of your printer, so the system is not affected by dirt particles or regular wash-downs.

  • Environmental impact – How do I make the process as sustainable as possible?

It’s good to understand the environmental impact of different technologies to adhere to sustainability regulations and growing environmental pressures.

  • Quality control and validation – Does the barcode need to be double checked by a vision system?

Using a camera system to double check date codes and highlight coding errors means improved accuracy, and fewer product recalls.

Benefits of printing variable barcodes away from the production line

Fast paced, high throughput production lines are, by nature, not ideal environments for printing quality barcodes. Achieving the correct print placement can prove difficult when you have unusual packaging shapes that cannot be accurately presented to the printhead.

Rather than go down the route of pre-printing and hand applying labels, you can use all-in-one feeding systems that are designed to print barcodes directly onto flat-form packaging. These can be fitted with a variety of coding and marking technologies, offering a more flexible solution that ensures consistent, high-resolution print.

Additionally, off-line feeders can be integrated with scanners, validation packages and additional accessories to guarantee that you are printing verifiable, scannable barcodes.

Why should you work alongside a GS1 partner?

Working with a GS1 partner opens up new opportunities for manufacturers. Who have access to:

Industry insights

Keep your team up to date on relevant advancements within the industry, including local, global and regulatory requirements.

A partnership you can trust

Standards adoption

Work to exacting standards accepted by all retailers, to achieve accurate traceability across the supply chain, and deliver peace of mind to consumers.

Aftercare fuelled by excellence

Global opportunities

Sell your products anywhere in the world, as GS1 barcodes and standards are accepted by all major retailers and markets.

Maintenance - free icon orange

Expert implementation

Solutions implemented by coding and marking experts who have continuous training on GS1 standards and experience across all production environments.

Expert advice

When it comes to printing variable information like barcodes, we’re the go-to experts. Our team of engineers are ready to walk you through your current process, identify areas for improvement, and deliver a solution that’s more efficient, capable, and cost-effective.

And if you’re venturing into the world of on-demand barcode printing for the first time, we’ll help you get started and make the implementation process a breeze.

Speak to us about your barcoding requirements

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