Batch coding is one of those jobs that nobody sees when it goes right - but everyone notices when it goes wrong. Whether you’re a small food start-up placing your first products on shelves, or a large producer running round-the-clock packaging lines, the need is the same: clear, consistent, compliant codes on every pack. But the type of batch coding machine you choose can look very different depending on where you are in your growth journey.
Below, I break down how the needs of start-ups and high-volume manufacturers differ, and which coding solutions typically fit best at each stage.
No matter the size of your operation, some fundamentals never change. Every food business must meet traceability rules, print accurate BBE/lots on every pack, and deliver codes that pass retailer quality checks. The big difference is how your production environment, materials, and speed affect the equipment that’s right for you.
Quick tip: Before comparing printers, make a list of your packaging materials. The substrate often decides the technology.
Most early-stage food companies face a similar mix of challenges. There’s usually a tight budget, a small team, and a packaging setup that may involve manual or semi-manual processes. Often the production environment is shared, changing frequently, or still evolving as the brand grows. Start-ups also tend to switch packaging formats more frequently as they test different designs or respond to retailer requests.
In short, the equipment needs to be affordable, flexible, and easy to use - because every minute spent fiddling with a printer is time taken away from getting stock ready to ship.
Typical start-up pain points:
For most small producers, thermal inkjet (TIJ) printers are the go-to solution. They’re low cost, require almost no maintenance, and deliver sharp, clean codes. Changing cartridges is quick and tidy, and most units can be mounted on a small bench or integrated into a simple workflow. If your packaging is primarily sleeves, cartons, labels, jars or pouches, TIJ is often the most practical starting point.
However, if you’re packaging in plastics, glossy films, or PET bottles, TIJ may not adhere properly - and that’s when an entry-level CIJ printer becomes the better option. CIJ gives you much more versatility with inks and substrates, and while there’s more maintenance involved, it ensures the code actually stays on the pack.
A simple rule of thumb:
Once you scale up, the picture changes dramatically. High-volume manufacturers need coding systems that work reliably at speed - often 200 to 1,000+ packs per minute - and operate in tougher environments such as chillers, washdown areas, or dusty bakeries. Downtime becomes incredibly expensive, and anything that stops the line quickly becomes a bottleneck.
Another consideration is integration. Large producers often want printers that connect to networked control systems, centralised message management, and vision systems that verify the codes. At this scale, consistency and automation matter just as much as print quality.
What matters most at high volume:
In busy food factories, industrial CIJ remains the workhorse. It’s fast, it prints on almost anything, and modern systems have long service intervals and automated cleaning routines that dramatically reduce operator intervention. CIJ is ideal for bottles, trays, films, caps, and most high-speed packaging lines.
For permanent, tamperproof coding - especially in dairy, beverage, and certain ready-meal applications - laser coding is increasingly popular. The upfront investment is higher, but with no consumables and minimal maintenance, the long-term running costs can be very attractive for large producers.
When coding directly onto flexible films or flow-wrap, thermal transfer (TTO) remains the gold standard. It delivers high-resolution prints and is ideal for date codes, batch numbers, prices, or even small barcodes.
Tip for scaling manufacturers: If your line speed is increasing or you’re adding SKUs, consider printers that offer remote monitoring and centralised control. It saves time and prevents coding errors.
Start-ups generally need to manage upfront cost and avoid anything that requires a lot of cleaning or engineering support. TIJ fits this space well because the cost is simple: a machine and cartridges, and that’s about it.
High-volume producers think differently. For them, downtime is far more expensive than the printer itself. That’s why industrial CIJ and laser systems - with their higher reliability and lower cost per print - tend to dominate at scale.
A quick comparison:
One of the biggest mistakes we see is companies choosing a coder without considering the substrate. A start-up may select TIJ because it’s cheaper, only to discover later that the ink won’t adhere to their new glossy pouch film. Larger producers may struggle with condensation or freezer-grade materials that need specialist inks.
This isn’t just a quality issue - it’s a compliance issue too. Codes must stay on the pack.
Tip: Always test ink adhesion on your actual packaging materials before committing to any machine.
As your output grows, so does the demand on your coding equipment. You may find your current solution starts to slow the line, clog more often, or struggle with new packaging designs. These are all signs that it might be time to step up to a more industrial solution.
Common triggers for upgrading include:
An upgrade at the right time can dramatically reduce waste, improve traceability, and keep you ahead of retailer expectations.
Start-ups and large food producers both need reliable batch coding, but the right machine depends heavily on your materials, speed, budget, and operational environment. TIJ is often perfect for new businesses because it’s simple and cost-effective. CIJ, laser, and TTO take over as you scale into high-volume production environments where reliability and integration matter most.
If you’re unsure what’s right for your setup, Contact us today and we will be happy to provide guidance, arrange a demo, or run sample prints on your packaging. The right coder doesn’t just print dates - it supports the growth of your entire operation.
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