7 Mistakes Manufacturers Make When Printing 2D Barcodes and How to Avoid Them

The transition from traditional 1D barcodes to 2D codes represents one of the most significant changes in product identification in decades. With the GS1 Sunrise 2027 (Ambition 2027 in the UK) initiative fast approaching, manufacturers across industries - from food and beverage to pharmaceuticals - are upgrading their coding infrastructure to handle data-rich 2D barcodes like QR codes and Data Matrix codes.

For engineering teams responsible for production lines, this is more than just swapping barcodes - it’s about ensuring precision, reliability, and scalability in high-speed industrial environments.

Here’s a breakdown of the seven most common mistakes manufacturers make when printing 2D barcodes - and how to avoid them using modern coding technologies like CIJ, TIJ, and laser systems.

1. Treating 2D Codes Like 1D Barcodes

Many teams assume that a line capable of printing 1D EAN/UPC codes can automatically handle 2D barcodes. The reality is that 2D codes require much higher print resolution and exact dot placement to ensure readability. Even minimal print drift can render a Data Matrix unreadable at retail POS.

How to avoid it:

Use printers engineered for high-resolution coding, such as Markem-Imaje 9330, 9410, and 9450 CIJ printers. These models deliver precise drop placement and advanced nozzle technology suitable for fine 2D patterns, even at high line speeds. For extremely detailed codes on small packages, consider TIJ printers or laser coders, which offer even sharper results on various substrates.

2. Ignoring Substrate and Ink Interaction

The substrate plays a critical role in code legibility. Printing a 2D code on glossy films, flexible pouches, or recycled cardboard can distort or blur the image if the wrong ink is used.

How to avoid it:

• Select inks formulated for high contrast, fast drying, and minimal bleed
• Conduct test runs on all production materials
• Use Markem-Imaje inks optimized for CIJ and laser systems, which maintain sharp edges and ensure reliable scanning, even on textured or dark substrates

3. Neglecting Code Size and Quiet Zones

Unlike 1D barcodes, 2D codes require specific module sizes and clear quiet zones around the pattern. Codes that are too small, too dense, or too close to other graphics can fail scans, creating expensive production reworks.

How to avoid it:

Follow GS1 guidelines for minimum module size and quiet zone requirements. Use in-line verification tools, like Markem-Imaje vision systems, to automatically check readability during production.

4. Overlooking Environmental Factors

Industrial environments - including temperature, humidity, line speed, and condensation - directly affect code quality. Beverage filling lines, for example, often present wet or humid conditions that can compromise CIJ ink adhesion.

How to avoid it:

• Use pressurised printheads and quick-dry CIJ inks designed for harsh conditions
• Consider enclosed laser systems for permanent, high-contrast codes on difficult substrates
• Printers like Markem-Imaje 9410 and 9450 offer environmental adaptability, ensuring consistent quality on demanding lines

5. Not Verifying Print Quality In-Line

Spot-checking codes during QA reviews is not enough. A single unreadable code can cause entire batches to fail retail POS scanning.

How to avoid it:

Implement in-line barcode verification systems integrated with your CIJ or laser coders. Automatic rejection, alarm triggers, and real-time reporting can prevent defective codes from leaving the line. Many Markem-Imaje printers include integrated vision modules for this exact purpose.

6. Neglecting Data Management and Traceability

A 2D barcode is not just an image; it is a data carrier. Incorrectly formatted or duplicated data undermines traceability and can breach GS1 compliance.

How to avoid it:

• Integrate printers with a centralised data management system or ERP
• Ensure all 2D codes are unique, verified, and formatted correctly before printing
• Markem-Imaje’s CoLOS® Software Solution can automate data validation across multiple production lines, reducing human error

7. Delaying Preparation for Sunrise 2027

Many manufacturers wait too long to upgrade equipment or processes, underestimating the time required for validation, line trials, and staff training.

How to avoid it:

• Conduct a coding readiness audit now
• Assess your current printers, including legacy CIJ systems, for 2D capability
• Plan upgrades to systems like Markem-Imaje 9330, 9410, or 9450, which are already engineered for 2D compliance and high-speed production environments

Early preparation reduces the risk of retail scanning failures and ensures compliance well before 2027.

Summary

Printing 2D barcodes is not a simple line-of-sight substitution - it’s an engineering challenge. By selecting the right equipment, optimising inks and substrates, integrating verification, and centralising data management, manufacturers can achieve high-quality, readable 2D codes at scale.

At Industrial Printer Services Ltd, we specialise in helping manufacturers implement CIJ, TIJ, laser, and print-and-apply solutions, with full integration into production lines for primary packaging, cases, and pallets. If you’re preparing for GS1 Sunrise 2027, now is the time to upgrade your coding systems and ensure full traceability and compliance.

Need help? Contact us today.