Is your production line ready for QR codes powered by GS1?

The move from traditional linear barcodes to QR codes powered by GS1 is gathering pace across the retail and manufacturing industries.

Retailers, including Tesco UK, are actively progressing the integration of these codes across their supply chains. Domino is working with Tesco UK on this transition, while Codico is the official distributor of Domino solutions in the Republic of Ireland and Northern Ireland and a GS1 Ireland Gold Partner.

For manufacturers, the important question is no longer simply whether QR codes are coming. It is whether their packaging and production lines are ready to generate, print and verify them reliably.

What is a QR code powered by GS1?

A QR code powered by GS1 can carry more information than a traditional linear barcode.

Using the GS1 Digital Link standard, the code can combine a product identifier such as a GTIN with variable information including:

• Batch or lot numbers
• Expiry, use-by or best-before dates
• Serial numbers
• Supplier or production information
• A web address linking to additional product content

The exact information required will depend on the product, retailer and application.

This additional data can support improved traceability, stock management, recall processes, waste reduction and access to product information. However, it also makes the printing and verification process more demanding.

Printing the code is only one part of the requirement

A production line must do more than place a QR code on a pack.

The code must contain the correct data, remain readable on the chosen packaging material and be printed consistently at normal production speeds.

A QR-ready production line should be able to:

• Generate the correct GS1 data structure
• Update variable batch and date information automatically
• Print consistently on the actual packaging material
• Maintain the required code size and quiet zone
• Manage contrast, reflection and packaging movement
• Verify the information contained within the code
• Inspect the physical quality of every printed code
• Alert an operator or reject a product when a code fails inspection

Required human-readable batch and date information must also remain visible and match the information encoded within the QR code.

A successful mobile phone scan is not enough

A code scanning successfully once on a phone does not prove that it will perform consistently in production or throughout the retail supply chain.

Code readability can be affected by:

• Glossy or reflective packaging
• Flexible film movement
• Poor contrast
• Insufficient space around the code
• Printhead condition
• Incorrect printer settings
• Changes in production speed
• Incorrect or incomplete encoded data

Testing must therefore take place using the actual packaging, intended data and normal production conditions.

Choosing the appropriate printing technology

There is no single printing technology that will suit every QR code application.

The correct solution will depend on the packaging material, available print area, line speed, required code size and production environment.

Potential technologies include:

• Thermal transfer overprinting for flexible films
• Thermal inkjet for high-resolution printing on suitable surfaces
• Continuous inkjet for a wide range of substrates and product shapes
• Laser marking for permanent, consumable-free coding on compatible materials
• Print-and-apply labelling for cases, trays and other secondary packaging

Sample testing is important before selecting or changing equipment.

Verification must form part of the solution

As retailers introduce more variable information into product codes, manufacturers must be confident that the correct information appears on the correct product.

An in-line vision system can inspect each code and check:

• Whether the code is present
• Whether it can be successfully decoded
• Whether the encoded data is correct
• Whether the batch and date information matches the production order
• Whether the print quality meets the required standard

The inspection system can then trigger an alarm, stop the line or automatically reject a non-conforming product.

This creates a controlled process covering both printing and verification.

Coding, vision and automation from one supplier

QR code implementation can involve several connected elements: the printer, production data, product handling, inspection, rejection and line control.

Codico can bring these elements together as one integrated solution:

• Domino industrial coding and marking equipment
• Selection of the appropriate printing technology
• GS1 data and production-line integration
• SICK in-line vision inspection
• Product detection and handling
• Automated rejection and line control
• Sample testing and production trials
• Installation, training and technical support

Codico is a GS1 Ireland Gold Partner and the official Domino distributor for the Republic of Ireland and Northern Ireland.

Already using another coding brand?

Your existing coding equipment does not prevent you from assessing your QR readiness.

Codico can review applications using equipment from another manufacturer and identify whether the existing installation can be retained or whether changes are required across printing, data integration, vision inspection or product handling.

The objective is to identify the most appropriate solution for the complete production process.

Start with one pack and one production line

Manufacturers do not need to review every product and production line at once.

A QR Readiness Review can begin with:

• One packaging sample or clear photograph
• The packaging material
• The current coding equipment
• Approximate production speed
• The information that will change on each product
• Details of any existing inspection system

Codico can then assess the application, arrange sample testing and identify the next steps required to make the line QR-ready.

Contact Codico to arrange a QR Readiness Review for your production line.