Barcode scanning is the backbone of modern industry, logistics, and commerce—speeding up data capture and minimising errors across the supply chain. At Kestronics, we know that even the best systems can be undermined by common scanning issues. In this article, we explore 10 frequent problems encountered in barcode scanning and offer practical solutions to ensure your operations run smoothly.
1. Inadequate Quiet Zone
Problem:
A barcode requires a clear area—the so-called quiet zone—around its edges to help scanners detect its start and end. When this space is compromised by nearby text or graphics, scanning errors can occur.
Solution:
- Ensure a quiet zone at least five times the width of the narrowest bar.
- Avoid placing any graphics, text, or other elements too close to the barcode.
2. Poor Contrast and Colour Combinations
Problem:
Barcodes printed with low contrast or unsuitable colour pairings (e.g. red on white, black on blue) are difficult for scanners to read reliably.
Solution:
- Use high-contrast combinations—preferably a black barcode on a white, non-transparent background.
- When standard colours are not an option, test alternative combinations to ensure readability.
3. Surface and Material Issues
Problem:
Glossy or reflective surfaces (such as varnished cardboard, aluminium, or film) can cause light to reflect unpredictably, interfering with the scanner’s ability to capture the code accurately.
Solution:
- Consider printing barcodes in reverse (using white bars on a dark background) on reflective surfaces.
- Select label materials suited to the environment, such as matte finishes for high-gloss substrates.
4. Subpar Print Quality
Problem:
Poor print quality—due to smudging, fading, or damaged labels—can render a barcode unreadable. Direct thermal printing, for example, is less durable than thermal transfer printing.
Solution:
- Regularly maintain printing equipment, including cleaning or replacing print heads.
- Opt for durable printing methods (e.g., thermal transfer printing) and high-quality materials to ensure long-term legibility.
5. Non-Compliance with Barcode Standards
Problem:
Barcodes that don’t adhere to industry standards (such as those set by GS1) may not be recognised consistently throughout the supply chain, causing integration issues with partner systems.
Solution:
- Follow established guidelines on dimensions, bar height, and background contrast.
- Use certification tools and services provided by organisations like GS1 to ensure compliance.
6. Software Integration Challenges
Problem:
Even if the printed barcode is perfect, software integration issues can disrupt the scanning process. Incompatibility between your scanning software and existing IT infrastructure can lead to delays or data loss.
Solution:
- Choose barcode scanning software that integrates seamlessly with your existing systems.
- Consider investing in supported, commercial solutions rather than open-source options if in-house resources are limited.
7. Limited Support for Barcode Symbologies
Problem:
With over 30 barcode symbologies available (UPC, EAN, Code 39, Code 128, Data Matrix, etc.), a scanning solution that doesn’t support the required formats can create bottlenecks.
Solution:
- Ensure your scanning software is configurable to support only the symbologies you need—improving scan speed and accuracy.
- Verify that your hardware is compatible with the barcode types used in your industry.
8. Environmental Factors
Problem:
Variable lighting, dust, dirt, and glare from reflective packaging can all negatively affect scanner performance, resulting in slow or failed scans.
Solution:
- Use scanners with built-in illumination or configure your devices to use the torch function in low-light conditions.
- Maintain a clean scanning environment and regularly clean scanner lenses.
- Upgrade to advanced software that can compensate for environmental inconsistencies.
9. Barcode Duplication and Cross-Contamination
Problem:
Duplicate barcodes or cross-contamination (when codes from different products mix) can lead to misidentification and tracking errors in inventory management.
Solution:
- Implement strict barcode verification processes during label production.
- Use smart data capture software that validates scanned codes against expected values and alerts users to discrepancies.
10. Human and Mobile Scanning Challenges
Problem:
Whether due to poor scanning techniques, ergonomic issues, or the limitations of mobile devices, human error remains a significant challenge—especially when using smartphones for scanning.
Solution:
- Provide comprehensive training on correct scanning practices, including proper angles and distances.
- Invest in pre-built mobile scanning interfaces that optimise user experience and reduce repetitive strain.
- Consider using ruggedised devices designed for demanding environments to minimise user-related errors.
Conclusion
Barcode scanning is a critical component of efficient supply chain management, but its success hinges on overcoming common issues—from quiet zone inadequacies and poor print quality to software integration and environmental challenges. By addressing these 10 problems head-on, you can improve data accuracy, boost operational efficiency, and enhance overall business performance.
At Kestronics, we are committed to helping you navigate these challenges with our innovative barcode scanning solutions. If you have any questions or need expert advice, feel free to contact our support team or explore our range of products.