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What Causes Unreadable Barcode Issues (Part 1)

Sep 4, 2020 | 1D Barcodes, 2D Barcodes, All Posts, Barcode Labeling, Barcode Scanner, Barcode Verification | 0 comments

Barcodes improve efficiency are vital to supply chains, inventory management, transportation, asset management, and more. Barcodes provide a means of knowing what a product is and where it goes. That is why when a barcode is unreadable for any reason, it decreases your efficiency and can cause chargebacks and lost shipments.

So, what causes an unreadable barcode? It could be any number of things. The most common reasons for unreadable barcodes are addressed in this first article of a 2-part series:

  • Poor contrast between the spaces and bars
  • Quiet zones around the barcode have marks
  • Damage or distortion to the barcode
  • Incorrect symbology used in 2D barcodes
  • Using the wrong ribbon and label combination
  • Printing too fast causing the label to smear

Barcodes provide a means of knowing what a product is and where it goes. That is why when a barcode is unreadable for any reason, it decreases your efficiency and can cause chargebacks and lost shipments.

Prevention is always cheaper than the consequences of losing assets and possibly even customers. The first thing you should always check is if your barcode printers are well-maintained, cleaned, and are using the labels per the manufacturer’s specifications. If you are still having problems, keep going to see if one of the issues discussed are relatable.

Poor Contrast

Barcode scanners must be able to differentiate between the light (spaces) and dark (bars) elements of a barcode. Low contrast between the spaces and bars of a barcode prevent the ability of scanners to decode and provide the right information.

A barcode label printer must be able to create uniformly light and dark elements across the entirety of a label. Any variations in the label substrates, harsh shadows, or reflections caused by lighting can cause a no-read or a mis-read.

Messy Quiet Zones

Quiet zones surround every barcode to let scanners know where the barcode is in comparison to the surrounding material. This area surrounding the barcode must be free of text and marks for a scanner to read the barcode accurately.

The quiet zone around a barcode is typically about 10x the width of the narrowest bar of a 1D barcode. 2D barcodes require an area of at least one element width on each side it. Anything within these areas of the barcode quiet zones create unreadable barcodes.

Damage and Distortion

Damage or distortion to a barcode can happen anywhere from printing, manufacturing, during shipping, and at the end user. Even if a product leaves your facility with a pristine barcode label, there is no guarantee that it will remain that way. Barcode labels can get scuffed, torn, become faded, and can be damaged by environmental conditions. Barcode labels can even shrink when exposed to moisture.

Incorrect Symbology

Incorrect symbology used in 2D barcodes can generate the wrong information for the product it is attached to. 2D barcodes can encrypt approximately 2,000 characters using patterns, shapes, and dots. Using the wrong symbology can cause a misread or no read, leading to wasted time and rejected shipments. Even worse, the wrong symbology can cause incorrect pricing and inventory disasters.

Wrong Label and Ribbon Combination

Using the wrong label and ribbon combination for the barcode label application will create a poor image due to poor printing, causing an unreadable barcode. Different product environments (such as heat, chemical exposure, extreme cold exposure, etc.) will most likely require different label and ribbon combinations.

Poor imaging on barcode labels can cause fatal results in pharmaceutical and biotechnology organizations. This can result in a stream of fines, lost customers, and possibly even lawsuits.

Printing Too Fast

The faster you print barcode labels the more heat is required of the printer for the barcode to properly dry and set on the label. The faster you want to print out labels, the more heat is needed to ensure the label data sets as it prints instead of smearing.

1D labels are printed like a picket fence (landscape or parallel) or ladder (portrait or perpendicular). Print speed can drastically impact symbol quality especially if the 1D barcode must be ladder oriented. Print speed can also impact the quality of a 2D symbol such as a QR Code or Data Matrix Code.

Do These Problems Sound Familiar?

While there are other things that can cause unreadable barcodes, the main causes include low contrast, quiet zone violations, damage distortion, incorrect symbology, wrong label/ribbon combination, and speed of printing. Most issues can be easily resolved using proper barcode verification and printing technology, and monitoring barcode label specifications.

Prevention is always cheaper than the consequences of losing assets and possibly even customers.

Unreadable barcodes do not have to be the bane of your company. The companion article to this layout of possible reasons for unreadable barcodes provides some solutions to each of the areas.

You can also contact us directly to discuss what we can do to find a solution for you.

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