Barcodes keep manufacturing and distribution operations efficient
The first barcode patent was issued in 1952 for labeling railroad cars. They weren’t used commercially until June 1974 when the first barcode scan took place on a pack of Wrigley’s chewing gum at a Marsh’s supermarket in the US state of Ohio. Since then, barcodes have expanded far beyond grocery aisles to power industries worldwide.
By providing instant, machine-readable information, barcodes streamline assembly lines, enable seamless product tracking, and reduce errors. Scanners read barcodes to identify items, track movement, update inventory in real time, and connect products to pricing, promotions, or digital experiences – all without manual entry. This helps companies move quicker, reduce errors, and serve customers better.
Understanding barcode symbology
Barcode symbology refers to the method used to encode data – whether with spaced lines, dots, or squares. Scanners decode these symbols to extract data for applications like pricing, order fulfillment, traceability, sortation, and shipping.
Available in both 1D and 2D forms, barcodes serve industries that manufacture, buy, sell, and distribute products. They can be applied using simple pre-printed labels, tags, or stickers, or through direct part marking (DPM), which permanently marks parts with methods like laser printing, dot peening, or engraving.
Choosing the right code symbology
Whether you’re managing inventory, streamlining distribution, or tracking items throughout their lifecycle, selecting the right barcode type is key to operational efficiency and traceability.
Here’s a breakdown of the most common barcode formats and where they’re used.
1D linear barcodes
1D (one-dimensional) barcodes are the traditional, widely recognized format. They store data horizontally using varying bar and space widths, scanned from left to right.
The narrowest bar – called a module – sets the base width for the code, with wider bars measured as simple multiples (2×, 3×, 4×, etc.). Most 1D barcodes follow wide-to-narrow ratios such as 2:1, 2.5:1, or 3:1.
Some versions encode only numbers, while others can include letters and symbols. Code height can be adjusted to fit different products while ensuring readability. The UPC, used on groceries and household items, is the most familiar example of a 1D barcode. Other common examples include:
- Code 39: A versatile alphanumeric barcode widely used for inventory and asset tracking.
- Code 128: A high-density barcode that enables fast, reliable data encoding across industries.
- EAN 13: The global standard barcode for retail product identification and scanning.
- GS1 DataBar expanded: A compact barcode that stores more information in a small space, ideal for fresh foods and retail items.
- GS1 omnidirectional: A barcode scannable from any angle, ideal for high-speed retail checkout.
- Interleaved 2 of 5: A compact numeric barcode designed for logistics and warehouse labeling.
Typical applications: Retail checkout, inventory tracking, shipping labels, asset tags
Here’s what each part of a 1D linear barcode code means.
2D matrix codes
2D (two-dimensional) barcodes store data both horizontally and vertically, allowing more information to fit into a compact square or rectangle. Each code is made up of uniform modules (small squares). These codes are highly readable, resilient to poor printing, and include redundant data, so they can still be scanned even if they are damaged.
Common types of 2D barcodes include:
Aztec barcode: A fast, reliable, and space-efficient code, ideal for tickets, boarding passes, and mobile scanning.
QR codes: A versatile code that connects people to digital experiences, from payments to product information.
Direct Part Marking (DPM) codes: A permanent, scannable mark that ensures traceability of parts throughout their entire lifecycle.
Typical applications: Healthcare records, mobile payments, marketing/QR links, airline boarding passes
Here’s what each part of a 2D matrix code means.
Keys to great barcode scanning performance
Start with the right scanner
Choose one with proper decoding capability, performance reliability, and connectivity for your manufacturing or distribution setup
Read rate is key
The percentage of successfully read barcodes indicates reliability. The closer to 100%, the more reliable the reader for factory or production environments.
Calculating read rate
If 9,900 barcodes are successfully read in 10,000 attempts, the read rate is calculated:
9,900 ÷ 10,000 = .99 or 99%.
Monitor print quality
High print quality ensures codes are readable across the distribution chain.
Data flow
Once scanned, data feeds into the management execution system (MES), with Ethernet offering the fastest, most reliable transfer.
Industry categories
From healthcare to food and beverage, barcodes support accuracy, efficiency, and innovation in industries across the globe:
- Automotive
- Beverage
- Consumer products
- Electronics
- Food
- Logistics
- Medical devices
- Pharmaceutical
- Semiconductors
- Solar wafers
Industry standards
Standards make barcodes universal, ensuring consistency, accuracy, and reliability, whether you’re scanning parts in a factory or products at checkout.