Unreadable packaging codes might seem like a small mistake, but their impact can be significant. When batch numbers or expiry dates can’t be scanned, production slows, shipments are delayed, and customer trust begins to fade. These small codes play a big role in ensuring traceability and compliance.
That’s why understanding the causes of unreadable packaging codes and knowing how to prevent them is essential for keeping operations smooth and reliable.
The Hidden Cost of Unreadable Packaging Codes
In manufacturing and distribution, unreadable packaging codes are more than a visual flaw. They are a direct threat to product traceability and compliance.
Unreadable codes often lead to:
- Product recalls due to misidentified batches
- Bottlenecks in warehouse operations
- Increased manual rework and quality inspection time
- Reduced overall equipment efficiency (OEE)
Packaging code errors can create significant bottlenecks in the supply chain, delay deliveries, and increase operational costs.
To prevent these costly setbacks, investing in reliable coding and inspection systems is no longer optional. It’s essential to ensure every product leaves your line with a readable, compliant code.
What Makes a Packaging Code Unreadable?
Several technical and environmental factors can make a packaging code difficult or impossible to read. Understanding these root causes is the first step to solving the problem.
Poor Print Quality
Ink smudging, inconsistent contrast, or low ink density can make codes fade or blur. If the ink doesn’t properly adhere to the surface, scanners may fail to read it.
Incorrect Printer Settings
Improper alignment, incorrect printhead distance, or insufficient drying time can all cause distorted prints especially in fast-moving production lines.
Material and Surface Challenges
Packaging materials such as glossy plastics, metalized films, or curved bottles present unique printing challenges. In such cases, traditional printing methods might not deliver consistent readability.
Environmental Conditions
Humidity, dust, and temperature fluctuations can affect ink performance and adhesion. Even small variations in lighting or surface texture can significantly impact barcode readability in automated systems.
Industry Examples of Code Failures
Unreadable packaging codes have been a recurring issue across multiple industries. Let’s see how this challenge appears across different sectors.
Food and Beverage
A beverage company faced recalls due to smudged expiry codes on glass bottles caused by condensation. This resulted in thousands of returned products and significant damage to consumer trust.
Pharmaceuticals
For pharmaceutical companies, even a single unreadable batch code can compromise compliance. Failure to trace specific lots may result in regulatory fines or patient safety risks.
Consumer Goods
In high-speed packaging lines for cosmetics and personal care, irregularly shaped containers often cause printing inconsistencies. Codes that are too faint or misaligned make it difficult for scanners to capture data during distribution.
Proactive Strategies to Guarantee Readability
To minimize the risk of unreadable packaging codes, manufacturers can adopt several proactive measures that combine process optimization and technology. Let’s take a closer look at these strategies.
Regular Print Inspections
Implement automated vision systems to inspect every printed code in real time. This allows immediate correction before the product reaches the packaging or shipping stage.
Standardized Printer Calibration
Routine calibration ensures optimal printhead distance, ink flow, and drying settings. It also helps maintain consistent print quality across multiple production shifts.
Suitable Ink Selection
Choose inks specifically formulated for different materials, such as fast-drying solvent inks for plastic or pigment-based inks for porous surfaces. This ensures durability and high contrast.
Employee Training
Operators must understand printer operation, maintenance, and quality control protocols. A well-trained team can quickly identify potential issues before they escalate.
Integrate Coding with Quality Systems
Connect your coding solution to manufacturing execution systems (MES) or warehouse management systems (WMS) for seamless data traceability and automated reporting.
Technology That Eliminates Readability Issues
If unreadable packaging codes have been slowing down your production, it’s time to explore smarter solutions. One of the most effective options is Continuous Inkjet (CIJ) technology fast, flexible, and built for various packaging materials and shapes.
Non-Contact Printing for Complex Shapes
CIJ printers can print on curved, rough, or uneven surfaces without smudging. This makes them ideal for industries that package irregularly shaped containers like bottles, tubes, or cans.
High-Speed and High-Contrast Printing
Modern CIJ printers can operate at high production speeds while maintaining sharp, high-contrast codes. This ensures consistent readability even under demanding conditions.
Durable and Flexible Inks
CIJ technology supports various inks, including UV-curable and heat-resistant types, which can withstand extreme production or storage environments.
For example, using high-quality inkjet systems with advanced contrast detection significantly reduces misreads and downtime in automated processes.
Why Working with the Right Partner Matters
Choosing the right printing partner is crucial to avoiding unreadable packaging codes. A trusted partner not only offers advanced technology but also provides training, support, and maintenance to keep your production running smoothly.
Working with an experienced provider like DSI Printer gives you access to reliable continuous inkjet printers designed for various packaging challenges.
With the right collaboration, code printing becomes the key to ensuring every code remains clear, readable, and compliant with industry standards.
If your business deals with curved or irregular surfaces, discover how to overcome these unique printing challenges, read about: How to Overcome the Challenges of Printing on Curved or Irregular Surfaces
See a complete list of Continuous Inkjet Printers here and start optimizing your production lines today.
References:
- https://www.automate.org/vision/tech-papers/the-most-common-causes-of-unreadable-barcodes
- https://lowrysolutions.com/blog/common-causes-unreadable-barcodes-solutions/
- https://www.inboundlogistics.com/articles/unreadable-gtl-barcodes-create-a-bottleneck/
