Whether you’re implementing a new warehouse management system or optimizing an existing one, barcodes are a crucial component to evaluate. Product, shelf, and bin location barcodes play a vital role in delivering the data your staff needs to operate efficiently. However, labeling without proper planning can lead to additional costs and operational delays.

Below are 7 essential factors to consider before labeling your products with barcodes, along with detailed insights to help you deploy a barcode system that is both effective and scalable.

1. Should you label each item, carton, or pallet?

Always label the unit that will be referenced in your fulfillment process. For example, if you receive goods by pallet but ship them by carton, consider labeling each carton. If you ship individual items from within cartons, those items should be labeled individually. When labeling each unit is impractical or too costly, you may opt for labeling the carton exterior.

✅ Additional Notes:

• For short lifecycle inventory, labeling each unit can accelerate traceability in case of defects or recalls.
• In omni-channel operations, individual labeling supports more flexible and accurate packing.

2. Where is the best place to apply barcode labels?

Consistent placement is key to warehouse efficiency. Typically, the front-right corner of a product is ideal. Avoid placing labels underneath, where they can be hidden when products are stacked. Labels should be easily visible without requiring operators to walk around the product.

✅ Additional Notes:

• For varied product shapes (round, flat, boxed), establish label placement guidelines for each type to maintain consistency.
• Train your team on proper label placement using visual guides or instructional videos.

3. Which barcode symbology should you use?

Code 128 is widely used, compact, and reliable—ideal for warehouse environments. Ensure you test it alongside other potential symbologies during your scanner compatibility assessment.

✅ Additional Notes:

• You may also consider QR Codes (for storing more data) or EAN-13 (common for retail packaging).
• Choose a barcode type that integrates well with your ERP or WMS to avoid compatibility issues.

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4. What is the optimal barcode size?

Assuming your product has sufficient space, assess the average scan distance—usually between 2 to 3 meters in a warehouse. Test various mil sizes (barcode line width) using real product codes and select the combination that delivers the fastest and most reliable decode rates.

✅ Additional Notes:

• Test on multiple types of scanners: handheld, overhead, conveyor-mounted, etc.
• The longer the barcode, the more limited the scanning range—always validate with actual use cases.

5. What label size should you use?

After determining the ideal barcode mil size, select the smallest standard label size that fits your barcode. Avoid non-standard dimensions (e.g., 1.5″ x 2.5″) to reduce printing costs. Instead, consider switching to a more standard size such as 2″ x 3″ for long-term savings.

✅ Additional Notes:

• Ensure the label doesn’t cover critical product information such as ingredients or usage instructions.
• Design the label layout carefully to include barcode, product name, internal SKU, and expiration date if necessary.

6. Should you use thermal transfer or direct thermal printing?

• Direct thermal: lower cost, doesn’t require ribbons, but labels are more prone to fading under heat or sunlight.
• Thermal transfer: uses ribbons but offers higher durability, ideal for inventory that remains in storage for over a year.

✅ Additional Notes:

• For warehouses with outdoor exposure or high temperatures, thermal transfer printing is recommended.
• Test printed labels under different temperature and humidity conditions to gauge real-world durability.

7. Can you reuse existing barcodes like UPC?

Many consumer products already have UPC barcodes. However, there are several factors to consider:

• The same product from different suppliers may carry different UPCs. A WMS must support cross-referencing.
• Different packaging levels (carton vs. individual unit) will have different UPCs.

✅ Additional Notes:

• Create a cross-reference table to unify multiple UPCs under a single internal SKU.
• Ensure your warehouse software supports multi-barcode mapping per product.

✅ Final Thoughts & Implementation Advice

Proper barcode labeling enhances accuracy, traceability, and warehouse efficiency. To maximize these benefits, businesses must carefully evaluate each stage of the labeling process—from choosing the right barcode format and label size to selecting appropriate printing technology.

By considering these 7 key factors in detail, you can avoid costly errors, boost operational performance, and establish a robust barcode system tailored to your supply chain.

 

Looking for expert help to implement a complete barcode system?

Get in touch with Beetech—Vietnam’s leading provider of RFID, barcode, and smart warehouse management solutions.

📧 Email: info@beetech.com.vn
🌐 Website: https://beetech.com.vn

Beetech – Smart, Scalable, and Efficient Supply Chain Solutions.