Fix Unreadable Barcodes Fast

Key Takeaways

Here’s how to handle unreadable barcodes in production:

Identify common issues like poor contrast, smudges, or quiet zone errors
Use barcode verifiers that comply with ISO and ANSI standard
Regularly test protocols to catch issues early

What causes an unreadable barcode?

Figuring out why some barcode reads fail is the first step in preventing costly setbacks. Doing that often starts with a barcode verification scanner: a device that grades the quality of 1D and 2D codes based on ISO or ANSI standards. These scanners are important in barcode tracking systems, using high-quality optics, advanced algorithms, and intuitive software to make sure your codes comply with the standards. When a barcode scanner fails to read a code, it points out an issue that can be identified and fixed.

Common causes of no-read scans include:

Damage from scratches or smudges
Poor contrast
Incorrect color choices
Distorted or inconsistent printing, such as warping on flexible packaging or faded ink
Insufficient quiet zones, the blank space surrounding a barcode

Addressing these issues often requires specialized tools, such as Cognex's DataMan barcode readers which improve traceability and efficiency in difficult conditions.

Every barcode scan matters: the costs of no-reads

Unreadable barcodes can stall production lines, trigger costly reprints, waste products, and result in chargebacks. A quick, successful scan keeps parts and packages moving, reduces errors, and decreases delays. But a “no-read” disrupts the flow – and if unflagged, it can introduce inaccurate or incomplete data into the master database, complicating tracking and traceability.

Catching unreadable barcodes early helps prevent supply chain headaches before they start. Here’s what can go wrong:

Time-consuming manual entries: when parts or packages are rejected, warehouse workers and shipping staff must manually input data, leading to fulfillment delays.
Increased human error: typing mistakes can cause tracking and inventory errors.
Rejected shipments: non-compliant products may be refused by major retailers, suppliers, and government agencies.
Costly fines: codes that do not comply with requirements can result in penalties.
Supply chain disruptions: unreadable barcodes can stall automated sorting systems, causing delays in distribution centers and logistics hubs.
Customer dissatisfaction: slow checkouts, incorrect pricing, or delayed orders can lead to frustrated customers and lost sales.

Introduction To Barcode Verification White Paper | English

Introduction to Barcode Verification Guide

Learn how barcode verification improves traceability and compliance by ensuring code quality and accuracy.

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Barcode Verifiers: the key to fixing unreadable barcodes

Any manufacturer involved in producing, printing, or marking barcodes risks wasting time, money, and resources without barcode verification. Unlike barcode readers, which only detect failed scans, verifiers look at barcode quality to identify and resolve issues before they cause disruptions.

Barcode readers detect whether codes scan or not, but don’t tell you why they fail.
Barcode verifiers test the decode process for symbology type, readability, weaknesses, compliance with industry standards, and also generate reports for retailers and regulators.

With the right verification tools and protocols in place, manufacturers can produce more high-quality codes and fewer unreadable barcodes.

How to test barcodes in 4 steps: 

Select the right barcode verifier
Identify symbology type and quality standards
To choose the right verifier model, consider the following:
What size are the printed barcodes?
Does the barcode verifier have a field of view wide enough for large barcodes and the high resolution needed for small codes?
Which standards must you follow, such as Global Standards 1 (GS1) or the International Organization for Standardization (ISO)? Three primary verification standards govern 1D, 2D, and Direct Part Marking (DPM) codes.
How user-friendly is the software for grading against these standards?
Create a barcode testing protocol
Barcode testing should be an ongoing part of standard operating procedures, especially to continuously improve printing and quality control. Establish a regular testing schedule and include a plan for corrective action to get back on track, if barcodes fail.
Determine what suits your needs
Do you need continuous barcode verification or random sampling? Typically, barcode testing occurs on a sampling basis, with checks at set intervals, such as every 20 to 90 minutes. The DataMan 475V series from Cognex offers inline verification, providing automated, high-speed quality checks directly on production lines, grading up to 20 codes per second, inline verification, providing automated, high-speed quality checks directly on production lines, grading up to 20 codes per second.