Effective Approaches to Enhance 2D Barcode Scanning in Adverse Conditions

In today's fast-paced world, 2D barcodes are indispensable in various industries, from retail and logistics to healthcare and manufacturing. Their ability to store large amounts of data in a compact format makes them a preferred choice for businesses.

However, scanning 2D barcodes in adverse conditions can affect scanning performance and reliability. Exposure to harsh conditions can also damage the barcode labels, potentially making them harder to scan.

This blog will explore effective approaches to enhance 2D barcode scanning.

Understanding the Challenges of 2D Barcode Scanning

Before diving into the solutions, it's crucial to understand the common challenges that can make a barcode unreadable:

• Damage or Wear and Tear: Barcodes can become unreadable due to physical damage. Scratches, fading, or smudges can make it difficult for scanners to detect the necessary patterns.
• Poor Lighting Conditions: Scanning barcodes in uneven or low-light environments can result in shadows or reflections, making the barcode unreadable.
• Blurry or Low-Resolution Images: When barcodes are captured in low resolution or with motion blur, the resulting image can be too distorted for accurate scanning.
• Curved or Deformed Surfaces: Barcodes on cylindrical or irregular surfaces may appear curved or warped, posing significant challenges for scanning.
• Direct Part Marking (DPM): Barcodes that are etched or printed directly onto parts with varying textures or dark surfaces can be difficult to read due to lack of contrast between the mark and the surface.
• Moiré Patterns on Screens: Scanning barcodes displayed on screens, like those on mobile devices or TVs, can result in a moiré pattern, which interferes with the barcode's readability.

Ways to Ensure Barcode Scanning Performance and Reliability in Harsh Environments

The said conditions give rise to a unique set of challenges in the adoption of barcode systems, potentially taking a toll on efficiency. Here are seven ways to enhance the performance and reliability of 2D barcode scanning in adverse conditions.

1. Durable Barcode Labels

In industrial settings, a variety of factors ranging from friction and moisture to high temperatures and exposure to chemicals can smudge or erase parts of a barcode label. An unreadable barcode is a massive inconvenience. It can also take up valuable time and cause bottlenecks by requiring workers to enter information manually.

If you expect your barcode labels to be exposed to harsh environments, it is imperative to invest in more durable barcode labels. Polypropylene is well-suited for labeling rigid materials and has excellent resistance against weather elements, scratches, tears, and to some extent – oil and chemicals. Polyester labels are a great choice for outdoor use such as labeling shipping containers, thanks to their water, weather, and abrasion resistance.

2. High Accuracy Scanning Software

Using good barcode scanning software can make a world of difference. It enhances the performance of your 2D barcode scanner, greatly improving the scanning accuracy and reliability. It is best to develop custom scanning software using a good barcode scanner SDK. This would enable you to integrate it with various specialized features, such as enhanced error correction to make damaged barcodes readable.

In regard to error correction, it is highly advisable to print barcodes with high error correction capability if the labels are likely to sustain damage. Both QR and Data Matrix barcodes offer up to 30% error correction. By leveraging this feature, you won’t have to worry as much about getting an unreadable barcode every now and then.

3. Specialized Barcode Scanning Technologies

The scanning conditions in rugged industrial settings are different from those in regular commercial environments. To adapt, you must incorporate specialized barcode scanning technologies that are optimized for the said environment. For instance, laser scanners are resistant to interference. This makes them great for scanning in environments with disruptive ambient lighting and/or high levels of dust. Known for their ability to overcome quiet zone violations and issues, imager scanners are yet another great option.

4. Adequate Lighting

Unlike business environments such as checkout counters, lighting is often an issue in industrial settings. Without sufficient ambient lighting, your scanners may struggle to detect and read the 2D barcodes. Something as simple as installing light sources in the area where the scans would take place can boost scanning reliability. In case it isn’t a viable option, consider getting barcode scanners equipped with lights or adaptive imaging technology.

5. Regular Maintenance and Updates

Regular maintenance is essential to ensuring the scanning reliability and longevity of any scanning hardware. However, this is especially true in adverse industrial environments. Dust, oil, and chemicals settling on the scanners must be cleaned regularly to prevent buildup. Similarly, the barcode labels must be wiped and cleaned regularly to keep them readable.

Consider implementing checks at the end of rigorous processes to identify and replace damaged barcode labels. Regular updates to the scanning software can help fix scanning issues and improve performance.

6. Enforcing Scanning Guidelines

Adopting the best barcode labeling and scanning practices can help mitigate the challenges significantly. For instance, proper barcode placement, mandatory quiet zones, and maintaining the correct distance at the time of scanning can significantly improve readability. Standardize barcode guidelines and enforce them through comprehensive employee training. This can go a long way in ensuring error-free and consistent data capture.

Conclusion

It’s safe to conclude that while adverse conditions pose challenges for barcode scanning, there are plenty of solutions to work around them. Do not let factors typical to industrial environments and logistical processes deter you from reaping the advantages of barcode technology.

Instead, take up a tailored approach to mitigate the challenges by implementing relevant measures.