When adding barcodes to corrugated shipping boxes, manufacturers and logistics providers have two primary technologies: print/apply labeling and inkjet coding.
Both methods have advantages and disadvantages, significantly impacting efficiency, accuracy, and cost-effectiveness. In this article, we’ll look at the details of each technique, exploring their differences and helping you decide which one suits your needs.
Print/Apply Labeling
Print/apply labeling involves printing barcodes onto labels, which are then applied to the shipping boxes using a label applicator. This method offers:
- High-resolution printing: Print/apply labeling produces high-quality barcodes with precise details, ensuring accurate scanning and reduced errors.
Since barcode symbol contrast is an inspected parameter during verification, the black print on a white background maximizes the barcode quality score. - Flexibility: Labels can be applied to various box sizes and shapes, making them ideal solutions for diverse product lines. Labeling systems can also apply one or more labels to adjacent sides of a shipping case or wrap a longer label around the corner.
However, print/apply labeling also has some drawbacks:
- Higher upfront costs: Label printers, applicators, and label materials require significant investment.
- Slower application speeds: Print/apply labelers are usually constrained by the printing speed which can be time-consuming, especially for high-volume production.
Labeling system OEMs have spent considerable time creating systems that separate the print speed from the application speed, which increases product throughput. - Downtime: Print/apply labelers must stop for label (and ribbon) roll changes. Zero-downtime systems are available, but they are more expensive and tend to be complicated.
Inkjet Coding
Inkjet coding uses a non-contact printing process to apply barcodes onto the shipping boxes directly. This method offers:
- Lower upfront costs: Inkjet coders are often less expensive than label print/apply systems.
- Faster application speeds: Inkjet coding can keep up with high-speed production lines, reducing downtime.
- Less waste: No labels are required, minimizing waste and environmental impact.
However, inkjet coding also has some limitations:
- Lower print quality: Inkjet coding can produce GS1-compliant ITF-14 barcodes, but it is not ideal for higher-density barcodes like GS1-128.
- Surface requirements: Inkjet coding requires a clean, dry surface, which can be challenging in dusty or humid environments.
As brands have moved towards recycled corrugated materials, this has tended to get to be more challenging.
Late-Stage Customization
Using a pair of 4-inch inkjet printheads per side of the case can allow the complete package to be printed, eliminating the need to purchase, store and manage inventories of preprinted materials.
Comparison Summary
| Parameter | Print/Apply Labeling | Inkjet Coding |
| Barcode Quality Score | ✅ A-B on ANSII Scale | ✖️ B-D on ANSII Scale |
| Flexibility | ✅ | ✖️ |
| Connectivity to Other Systems | ✅ | ✅ |
| Upfront Costs | ✖️ | ✅ |
| Cost per Print | ✖️ | ✅ |
| Sustainability | ✖️ | ✅ |
Choosing the Right Method
When deciding between print/apply labeling and inkjet coding, consider the following factors:
- Production volume: High-volume production may benefit from inkjet coding’s faster application speeds.
- Barcode quality requirements: If GS1 128 barcodes are required, print/apply labeling is usually the better choice.
– Besides better print quality with thermal and thermal transfer label printing, the lower contrast when printing with black ink directly to brown corrugated results in verification scores that might not reach GS1 or the customer’s requirements.
– Note that when printing the ITF-14 barcode, a more lenient verification score is allowed as long as the barcode x-dimension (width of the smallest bars) is 0.025 or above. - Product Handling: Inkjet printers have a limited throw distance for the drops of ink that make up the image. This means that accurate product handling is needed to ensure the surface of the box is always accurately presented to the printer.
– If barcodes need to be printed to both the side and front/rear of the box, the package will need to be turned through ninety degrees before reaching a second printer. This can complicate the conveyor system.
– Finally, it is important that the conveyor runs smoothly through the inkjet printing stations. Any variations will be reflected in the quality of the printed barcodes.
Labeling systems such as ID Technology’s CarbonFlex are much more forgiving of poor product handling. - Costs: Good quality print/apply labelers often cost more than case coding inkjet systems, and operating costs are also higher.
- Environmental impact: If minimizing waste is a priority, inkjet coding is a more eco-friendly option.
Pressure-sensitive labeling produces a lot of waste in the manufacturing process and with waste liners and thermal ribbons on the packaging line.
Rolls of labels are heavy items to ship, which also adds to the carbon footprint.
Bottles of ink for inkjet printers are much smaller to ship and store, and for corrugated applications, the inks are water-based and somewhat environmentally friendly.
In conclusion, both print/apply labeling and inkjet coding have their strengths and weaknesses. By understanding your specific needs and weighing the advantages and disadvantages of each method, you can make an informed decision and optimize your barcode application process for corrugated shipping boxes.
