Nine Factor to Consider When Selecting Barcode Labels

Consumable media is a critical component of your printing system. Having the correct labels for your application can improve accuracy, lower material handling costs, and make your warehouse operation more efficient. With that said picking out the right labels can be a difficult procedure. But, if you remember the nine letters inB.A.R.C.O.D.I.N.G. you shouldn’t have a problem.

B – Barcode Scanner: What kind of scanning device will you be using to read your barcodes. Labels can have different light absorbing characteristics, which can improve the performance and efficiency of your scanner.

A – Attach: What surface will your labels be attached to? Smooth, rough, grooved, curved, or dirty surfaces can all AFFECT your label selection.

R – Rate: How many labels are you printing per minute? Per day? Per week? Per year? Labels have many different materials and qualities, so the kind of labels will be one factor in determining the final cost.

C – Clock: How long must the label last? What is the shelf-life of the product the label is on? Is it a mailing label to be used once or an asset label that needs to be on a fixed asset for life? This factor will not only determine the kind of label, but possibly the kind of printer!

O – Operating Environment: One of the most important considerations is the operating environment the labels will be exposed to. Will the label be exposed to extreme heat or cold, dryness or wetness, light, extreme handling, or chemicals. If so, there is a label for you, and Barcoding.com can be your supplier.

D – Do-it-yourself: Did you know that you do not have to buy a printer for every label application? Some applications, like tracking Fixed Assets with RioScan’s Fixed Asset software, require only pre-printed labels.

I – Inches: It is a matter of inches! The simple question, “how big is my label?” is the first consideration. Choosing a label with a common size, or “stock size” can help reduce costs. Labels can come as small as 1/8″ x ½” or as large as 11″ x 17″.

N – Need: What exactly is you labeling need? For example, some barcoding applications occur on tags that hang from an item, rather than stick to it. There are many different ways to barcode on item such as hanging tags, ID cards, metal tags, and direct print. Make sure that labels will suit your needs best.

G – Glue: The type of glue used to adhere the label to your surface is very important. Do you want your label to be permanently adhered to the surface or you do want it to be removable? Should your label leave behind a tamper-indication if is played with or is it important for the label to leave behind little to no residue when it is removed? These are all important questions and viable options for your labels program!

Other Factors that Affect Barcode Labels

BAR HEIGHT

For hand-held readers, bar height is at least one-quarter of an inch or 15 percent of the entire code’s length, whichever is greater.

“X” DIMENSION

The “X” dimension is the width of the narrowest element of the barcode. Other elements of the code are multiples of the “X” dimension.

CHARACTER DENSITY

Density refers to the number of characters which can be encoded in a given unit of length and is vitally important to the eventual application of a barcode.

CONTINUOUS/DISCRETE

Barcode symbologies are either continuous or discrete. Continuous symbologies use the intercharacter gap as a character, whereas discrete symbologies do not.

FIRST PASS READ RATE

The first read rate is the ratio of the number of successful reads to the number of attempted reads.

RIBBON FACTORS

The principal rule to remember with ribbons is that the ribbon you use in the office will probably not meet the specifications or requirements of the bar coding environment.

LAMINATES

In many ways, the specifications which apply to paper also apply to laminates. Laminates should not interfere with the scanning ability of the barcode reader.

ADHESIVES

Adhesives vary with each application. Some require labels to permanently affixed to an item, such as a piece of capital equipment.

by: Amy Packer

Do you know how Bubble Wrap was invented? I certainly didn’t until I started writing this blog post. Alfred Fielding and Marc Chavannes invented bubble Wrap in 1957. The pair of inventors sealed together two shower curtains creating many air bubbles trapped in between.  Originally and unsuccessfully marketed as wallpaper, the duo sold their product as green house installation and then in 1960 its use in protective packaging was discovered. IBM was the first client to use the product to protect a model 1401 computer during shipment.  Alfred Fielding and Marc Chavannes were inducted into the New Jersey Inventors Hall of Fame in 1993.

The following sections will help you understand the differences between the technologies and how to select the appropriate print method for your application.

Direct thermal printing uses chemically treated, heat-sensitive media that blackens when it passes under the thermal printhead. Direct thermal printers have no ink, toner, or ribbon.

Their simple design makes thermal printers durable and easy to use. Because there is no ribbon, direct thermal printers cost less to operate than inkjet, laser, impact, and thermal transfer printers. Most mobile printers use direct thermal technology.

Thermal media images may fade over time. If the label is overexposed to heat, light, or other catalysts, the material will darken and make the text or bar code unreadable. For these reasons, direct thermal printing is not used for lifetime identification applications. The readability of direct thermal labels, wristbands, and receipt papers varies greatly, depending on the usage conditions, but the technology provides ample lifespan for many common bar code printing applications including shipping labels, patient and visitor identification, receipts, and ticket printing.

For example, direct thermal labels can easily remain scannable after spending six months in storage in a distribution center, and direct thermal patient wristbands have a special coating that makes them water- and chemical-resistant. Common thermal printing applications include: shipping labels, including compliance labels; receipts; pick tickets; coupons; event tickets; citations and parking tickets; name tags; visitor passes; and more.

In thermal transfer printing, a thermal printhead applies heat to a ribbon, which melts ink onto the material to form the image. The ink is absorbed so that the image becomes part of the media. This technique provides image quality and durability that is unmatched by other on-demand printing technologies.

Thermal transfer printers can accept a wider variety of media than direct thermal models, including paper, polyester, and polypropylene materials. Thermal transfer printers can create extremely durable wristbands, asset tags, and certification labels, in addition to common labels, tags, and tickets. The specific label material and ribbon must be carefully matched to ensure print performance and durability.

By selecting the right media-ribbon combination, as well as specialty adhesives, users can create archival-quality labels to withstand temperature extremes, ultraviolet exposure, chemicals, sterilization, and more. Typical thermal transfer applications include: product identification; circuit board tracking; permanent identification; sample and file tracking; asset tagging; inventory identification; certification labels such as UL/CSA; laboratory specimens; cold storage and freezers; and outdoor applications.

Read about Dot Matrix, Ink Jet, Laser and Direct Thermal to see how Thermal Transfer stacks up against these other variable imaging technologies.

Dot Matrix

One of the first printing methods developed, dot matrix printing uses tiny round hammers to pound ink from a coated fabric ribbon onto a substrate – typically paper, which must be pin fed into the printer. Normally dot matrix printers use one or two column dot hammers – the more dot hammers on the print head, the higher the resolution.

Advantages

Dot matrix printers are readily accessible and very inexpensive – most typically used to type forms, checks, and other documents that require carbon copies. Since the pressure applied by the print head to transfer the ink ribbon to the paper helps create a carbon copy, the dot matrix process is extremely useful for record keeping. Due to multi-pass, ribbons for dot matrix printers are relatively inexpensive.

Disadvantages

Primary drawbacks include low print quality, limited graphic print capability, very slow print speeds, noisy operation, and a lack of resistance to chemicals. For bar code printing, especially, a defined image is crucial. The edge definition of dot matrix images is rarely clean or linear – greatly compromising the integrity of the bar code. Dot matrix printing’s poor image quality, combined with its low printing speed and inability to resist chemical solvents, severely inhibit its performance – serious concerns which can greatly increase costs to manufacturers.

Ink Jet

There are basically two types of ink jet applications for bar code printing – direct print applications and label applications. Direct ink jet printing is very effective for printing bar codes and expiration dates directly on canned foods, liquid bottles, etc. For these uses, a special direct ink jet printer is necessary – these machines are very expensive, and are usually incorporated directly into the assembly line. Ink jet technology can also print bar codes on labels using a standard office printer.

The serial printing technology of ink jet printing is conceptually very similar to dot matrix – ink applied to a substrate in an up-and-down or side-by-side droplet form by pressure – however, the actual delivery method of ink jet printing differs from dot matrix substantially. Ink jet printers do not use direct pressure for the transfer process, nor do they rely on ink ribbons – instead, they use a combination of liquid ink, ultrasonic pressure and an electrostatic field. Ink jet printers create images by propelling ink into tiny, highly controlled jet streams and onto the substrate. The quality of ink jet images is determined by the size of the ink droplets – small droplets produce cleaner lines, large droplets tend to blur.

Advantages

Ink jet printing technology is virtually the only solution for direct printing on a wide variety of substrates – from cartons and cans to plastics, glass, and paper. Assembly line ink jet printing can print at extremely high speeds and code large quantities in seconds. It is the most efficient method for alpha-numerical coding of consumer goods.

Disadvantages

While ink jet printers do allow users to have more flexibility, their low image resolution, limited durability, and high unit price make them a less attractive option for bar coding purposes. Although assembly line ink jet printing services a large audience, it is a very niche application, and the printers tend to be extremely expensive. Ink jet printing is also less solvent resistant, and specialty inks are required for high speed assembly line printing – a factor which entails costly maintenance and frequent routine attention. The ability of ink jet printers to print directly on many substrates makes it a very useful printing technology; however, for bar coding projects that require quality high resolution and good durability, thermal transfer printing is by far the better choice.

Laser

Laser printing, much like photocopying, uses a light source to generate an exact duplicate of the image it receives. The light source – a laser beam – creates an electrostatic image that is then charged onto a photoreceptor; the electrostatic charges from the photoreceptor attract the toner to produce the printed image.

Advantages

The laser printing process produces beautiful, dense, high resolution images for text and graphics.

Disadvantages

For bar coding purposes, the most serious constraint of laser printing technology is its substrate limitation. Laser printers can only print on certain types and sizes of labels – and certainly not directly on any non-paper surface, such as plastic or metal. Laser printing is also not the fastest option, and laser images are far less durable than thermal printed images. Toner cartridges and drum kits used in the laser printing process are extremely expensive, and hazardous if not disposed of properly. While the images produced by laser printers are much cleaner than those of ink jet printers, the lack of versatility, durability, and environmental safety – combined with high unit and maintenance fees – typical of laser printers certainly makes laser printing a less efficient alternative for bar coding.

Direct Thermal

Direct thermal printing uses virtually the same process as thermal transfer printing – with one exception. Direct thermal printers do not use ribbon. In direct thermal printing, the thermal process occurs on the paper substrate itself – requiring a specially coated paper for optimal performance. The heat generated from the print head causes a chemical reaction with the top layer of the coated paper that essentially burns the transmitted image onto the paper.

Advantages

Images produced by direct thermal printing are clear and defined; and direct thermal printers are cheap, simple to operate and easy to maintain. Direct thermal printing for bar code labeling is certainly an improvement over ink jet and laser technology, especially when it comes to speed and resolution.

Disadvantages

Direct thermal images are far less durable than thermal transfer printed images; and direct thermal technology is also constrained by substrate restrictions. The coated paper required by direct thermal printing is very sensitive to light, heat, and abrasion – limiting the range of applications for direct thermal printing to short-term projects. Direct thermal images have no chemical resistance, and very short life spans. Primary uses for direct thermal printing are “Point-A-to-Point-B” applications, such as baggage checking in airports, or parcel delivery. Bar coding projects requiring durable images and substrate flexibility are not well served by direct thermal printing technology.

but many competi tive ribbons are high in static – attracting dust, contaminates

and lots of problems. Dust leads to poor print quality, which leads to poor

scan rates, which leads to chargebacks and, in some cases, printheads

that fail way before their time. For problem-free printing, the choice is very

clear. Ask for TR4085plus®, the ribbonthat attracts praise not problems.

To learn more about TR4085plus®and its ability to shield against

static, or to request a copy of the independent lab testing, call

1-888-238-0162 or contact your Hughes sales representative.

2. Quality decreases. The number of out-of-spec or rejected containers increases.

3. Changeover time increases. The cost associated with this type of downtime can really add up.

4. Jams and failures due to damage and deterioration. On a rotary glue labeler, glue build-up on each station tends to be a problem. Sometimes, operators then unwittingly damage the labeler by using screw drivers or other tools to scrape away the glue. This damage over time can contribute to increased jams and failures.

5. Maintenance increases. Some companies use specialized maintenance software like MP2 to not only help keep maintenance running smoothly and avoid surprises, but to track equipment maintenance trends to provide the big picture.

6. Component obsolescence. Parts are no longer available from or supported by the machinery manufacturer or third-party suppliers, including old PLCs, proprietary controllers, or even outdated servo gear.

7. Requirements change but the line does not. Marketing may want a new package format or a new size. Replacing may be a better option than modifying the labeler to do what it wasn’t designed to do.

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