The variety of technologies available for barcode printing can be overwhelming. Further complicating the decision is whether it is better to invest in a barcoding system or to purchase pre-printed barcode labels. Deciding between these two options depends on factors such as the volume of labels needed and the budget allocated. Companies with high-volume needs might find it more cost-effective to invest in a barcode system, while those with smaller requirements may find purchasing pre-printed labels more suitable.
Thousands of companies have benefited from ordering preprinted barcode labels from service bureaus rather than investing in a barcoding system. Preprinted labels are useful in operations that require only a low volume of identical (i.e., fixed, non-variable data) labels, often with extensive use of colors or graphics.
However, companies that start with preprinted labels quickly discover the limitations of this solution option. Besides restricted flexibility, the use of preprinted labels prevents companies from including variable customer data or combinations of text and barcode information.
As a result, most companies find the financial commitment of printing on-demand barcodes worth the initial investment because of the added value from printing customized information on each label. For many applications requiring high-volume, mission-critical labels, the added cost of preprinted labels quickly exceeds the cost of the entire system. To the surprise of many barcoding novices, most of the companies that order preprinted labels also have barcoding systems. The preprinted labels are ordered with the necessary color, graphics or standardized text (such as return addresses on shipping labels) and are then fed through a barcode printer to receive customized (i.e., variable) information.
Whether a user elects to use preprinted or plain labels, media selection is critical to the success of any barcode integration. The variety of ribbons, paper, and synthetic labels and tags is too great for discussion in this document, but the barcode application, the intended life span of the label, and the environment to which the label will be exposed all have a direct impact on media selection. It is advisable to pretest a variety of media in an application before purchasing mass quantities.The variety of technologies available for barcode printing can be overwhelming. Further complicating the decision is whether it is better to invest in a barcoding system or to purchase pre-printed barcode labels.
Individuals new to barcoding often gravitate toward familiar technologies (such as laser printers, dot matrix printers or ink jet printers) that are already connected to a network and, therefore, deemed suitable for barcode labeling. While these printers can be used for some applications, they are often not the ideal solution for professional barcode labeling. The common limitations among these traditional office technologies include print speed and flexibility, as well as the inability to print labels that are durable enough or have the longevity or clarity required for all but the most basic barcoding applications.
Dot matrix technology uses a hammer or pin to transfer pigment from a ribbon onto the substrate (see Figure 1). Due to the inaccuracy of dot placement and low resolution of the printing technology, these printers are nearly unusable for barcoding.
Dot matrix printers, while considered a more traditional printing technology, continue to offer several advantages that make them a valuable choice in specific applications. Their unique capabilities and cost-effective features ensure their relevance, particularly in environments where durability and versatility are paramount. Below are some of the key benefits that highlight why dot matrix printers remain a practical option for various printing needs:
While dot matrix printers offer several advantages, they also come with a set of limitations that can impact their suitability for certain tasks. These constraints stem from their design and technology, which may not align with the demands of more modern printing requirements. Below are some of the key limitations that should be considered when evaluating dot matrix printers for specific applications:
Inkjet printing is used primarily for printing cartons or product packages with barcodes and human-readable data at very high speeds. Inkjet printers spray the ink onto the label surface in either a continuous stream, covering the entire print width with one spray, or one drop at a time (see Figure 3). However, inkjet printing is not acceptable for most barcoding applications.
The laser printer works much like a photocopier; it projects controlled streams of ions onto the surface of a print drum, resulting in a charged image. The charged image then selectively attracts toner particles, transferring the image onto the paper substrate. After the image is transferred to the media, the heat and pressure of the fuser cause the image to adhere to the media.
The most widely used technologies for dedicated barcoding systems are direct thermal and thermal transfer printing. While both technologies use a heated printhead to create the image on the label, they are suited to different applications.
There are two type of thermal printing technologies to print a barcode, direct thermal and thermal transfer. While there are distinct differences, in both cases heat is used for the print process. Direct thermal printing uses heat sensitive media, which is chemically treated, that blackens when passed under a thermal printhead. Conversely thermal transfer printing creates long-lasting images on various materials by using a heated ribbon in the process.
You can learn more about Direct Thermal and Thermal Transfer Printing by reading our dedicated FAQ which looks into the main differences between Direct Thermal and Thermal Transfer Printing.
Though the advance of barcoding has created new data management opportunities, much of the potential of barcodes remains untapped. Most barcode printers are connected to stand-alone personal computers (PCs) that control the barcode label design and function via a network print server. While these stand-alone systems, dubbed “island systems,” can still take advantage of barcode scanning to provide data automation, human users must direct the printer to print and manually enter nearly every piece of information.
More recently, enterprise resource planning (ERP) software has given barcoding an enhanced role in corporate information systems. In island systems, the barcode printer has no direct interaction with the corporate enterprise. When connected to an ERP system, the printer can take direction from other processes and print and encode data automatically when the server directs it to do so.
ERP systems, when used alone or partnered with warehouse management software or supply chain management applications, are capable of producing detailed reports based on the information they gather from the system operations. This reporting capability can be used with barcode integration software to print labels containing this same information.
Technology | Print Quality | Scanner Readability | Initial Installation Cost | Long-Term Maintenance Cost | Materials Waste |
Dot Matrix | Fair | Low | Low / Moderate | Moderate / High | High |
Ink Jet | Moderate | Low / Moderate | High | Moderate / High | High |
Laser | Moderate | Moderate | High | Moderate / High | High |
Direct Thermal | Moderate / Excellent | Moderate / Excellent | Moderate / High | Low | Low |
Thermal Transfer | Excellent | Excellent | Moderate / High | Low | Low |