How to optimize barcode and 2D code printing for secondary packaging

Moving barcodes and 2D codes from the print controller to cartons requires careful attention to print parameters such as DPI and proper selection of inks and print technology for your application. Read on to learn about four key mistakes you want to avoid when printing codes on secondary packaging.

Are you struggling with poorly printed barcodes on cartons and cases?

Creating quality barcodes and 2D codes that scan every time is a challenging task – especially when you have frequent changeovers and a wide variety of case sizes and materials. You need to ensure the right codes go on the right cartons, and they are clear, precise and scannable every time.

But carton and case coding is just a small process in the whole production line, so is modernizing your printing systems really worth the investment?

The answer is a resounding “yes.”

Don’t gamble with your scannable codes

If you don’t invest in getting your barcode printing right, the consequences can be expensive. Let’s paint the picture.

• Low-quality barcodes lead to scanning errors in warehouses and distribution centers, which can cause inventory discrepancies and shipping delays.
• Cartons with unreadable codes may be returned, resulting in additional handling, transportation expenses, and costly rework – for all of which you’ll have to foot the bill.
• Worst, consistent issues with code readability can damage a company’s reputation, leading to lost customer trust and strained relationships with retailers.

The bottom line? Outdated coding systems can be a liability for your business. Investing in modern printer technology will deliver a return on investment in ways you didn’t realize you needed.

Four code printing errors to avoid

Various issues can affect barcode and 2D code quality, from print contrast to print resolution. Let’s look at four common code printing errors that while avoidable, happen far too often.

1. DPI too low for the intended code size

Dots per inch (DPI) determine the resolution of the printed code. A high DPI means the printer produces more dots per inch, creating sharper images than low-resolution printers. On the other hand, a low DPI can result in blurred or pixelated codes that are hard to scan – even though they may look passable to the human eye.

Matching the DPI to the code’s intended size is essential to ensuring scanability.

As a rule of thumb, for larger code you can use a lower DPI setting (150-200 DPI), while for smaller codes you’ll need to print at higher resolutions (300-600 DPI). The good news is that no matter which route you choose, it makes no difference to the reader.

2. Poor ink quality

When it comes to inks, you get what you pay for. The quality of ink used in direct code printing or label printing significantly impacts the readability and durability of the codes.

Do not be fooled by third-party suppliers offering cheap inks because that’s what they are – cheap. And opting for cheap, low-quality inks can seriously affect the quality of both barcodes and 2D codes.

Poor-quality inks often result in poor-quality prints that fade, smudge, are uneven, cannot be read by the human eye or vision systems, and ultimately damage your brand’s reputation. Moreover, they tend to clog printhead nozzles, causing frustrating downtime, unnecessary maintenance expenses, and potentially long-term damage to your equipment.

The solution is simple: choose high-quality, durable inks that deliver quality prints at speed. Learn more in the blog post Understanding Ink to Drive Marking and Coding Success. Our quality-tested inks guarantee seamless operation in Matthews Marking Systems’ printers. They are made from premium ingredients to ensure dependable outcomes while contributing to the sustained functionality of your printing systems.

3. Low contrast

For efficient scanning, all codes require sufficient contrast between the dark portions and the light spaces for consistent scanning. The darkest sections must reflect less than half the available light compared to the background, a metric known as minimum reflectance or MR. If the background is too dark or the barcode too light, the code will fail.

This can be a tricky balance to achieve with unbleached brown kraft and corrugated boxes and cartons typically used for secondary packaging. These substrates have relatively low reflectance value; in other words, they don’t reflect enough light to provide sufficient contrast in every case.

This makes it imperative that the printed code be as dark and dense as possible, but also not excessively spread out or smeared as more ink is applied to achieve a darker shade. This is no easy task on highly absorbent paper-based packaging materials. Here’s where it’s vital to work with a marking and coding partner who understands these nuances and can perform the necessary testing and optimization to obtain the desired outcome.

4. Inappropriate printing technology

Choosing the ideal technology based on your needs is essential for optimizing code printing while keeping the cost per mark as low as possible.

For a detailed comparison of barcode and 2D code printing technologies, download our eBook: Solving Secondary Packaging Coding Challenges: The Definitive Guide for Co-Packers and Private Labelers.

Another critical consideration is whether to use direct printing or print-and-apply labeling.

Print-and-apply labeling refers to a machine that prints information on labels and applies them directly onto products and packaging, such as cases and pallets. The process is automated to apply a label to any side of a box or case, and software enables operators to create and change labels easily.

If you supply products to large retailers or plan to do so, you might not have a choice because their supplier standards often specify that they only accept labels for case coding. The key is looking for a label printer applicator, like the MPERIA A-Series, that boasts exceptional print quality to ensure labels fully comply with strict GS1 standards.

On the other hand, direct-to-case marking involves printing codes directly onto cases without backing paper or labels. Several marking technologies are viable options, including thermal inkjet, piezo inkjet, and valve inkjet. The significant advantages of direct marking as outlined in the blog post Direct Case Coding or Labeling? are the lower cost due to less expensive consumables (no need for labels) and more flexibility, as direct marking works on a wide variety of materials and has the flexibility to print the codes you need.

Our free eBook, The Definitive Guide to Secondary Packaging Labeling, Coding & Marking for the Co-Packing Industry, helps you weigh the pros and cons of direct printing vs. labeling to make an informed decision—download your copy now. Or for a free consultation, complete the contact form below and an expert will be in touch promptly.