2D vs 1D barcodes - what does it mean for POD

Andrew Smith, Founder | MD, ZenSmart

The humble barcode has been in the news in the last couple weeks.? GS1, the global non-profit organization that creates and maintains the standards for supply chain communication, including the barcode itself, has set a goal of widespread adoption of 2D-style codes by 2027 as part of its Sunrise 2027 initiative (ambitious).??

They are doing this because the 2D barcode enables a whole range of benefits in mass consumer goods supply chains.? You can do things like store use-by dates, batch numbers, ingredients, chain-of-custody and other similar information inside the information dense 2D barcode.? 1D barcodes on the other hand, store limited information in a linear format.? So the logic for 2D barcodes is pretty strong.

The 2D barcode has implications for Print on Demand manufacturers and our recommendation is that POD shift to 2D.? The key reasons why we recommend this change are:?

1. Use 2D barcodes where high speed label production or high volume scanning is required

1D barcodes only have room for a short identifier in their encoding logic and you need to call a centralized database to retrieve associated details, while 2D barcodes can store the complete, complex, actionable information directly in the code itself.? This independence from external systems is important where speed is critical.? Because your local device knows what to do by reading directly from the barcode, you eliminate delays and enable faster performance.? For example you may need to generate a pre-consigned shipping label on a high speed automated shipping line, a QR code can store the customer and address information natively in the label enabling totally local label production (i.e. removing database and network latency).? This could save 1-3 seconds per label.

2. Streamlined finishing automation

Instructions for machines can be embedded in the 2D barcode.? For example print settings or cutting parameters—can be encoded directly into barcode rather than calling recipes on the device.? The 2D barcode can directly configure the machine rather than being locked into pre-configured recipes. This ensures accurate setup, reduces manual intervention, and minimizes errors.

3. They are smaller

Because the data is encoded in 2 dimensions they can be made a lot smaller and still scan fast and accurately.? This makes them a lot less intrusive on things like banner sheets in photobooks than 1D barcodes or clothing tags can be designed entirely for branding purposes. Less real estate spent on barcodes means more real estate for human-readable information, branding and assets that improve the customer experience.

4. More accurate

The way the data is encoded with embedded checksums means that the accuracy of scanning is significantly higher than 1D barcodes.? A 2D barcode can be scanned at angles and distances that a 1D barcode can never be read at.? This means fewer re-scans and higher efficiency.

5. You can embed information that is of customer benefit in a 2D barcode

2D Barcode formats such as QR and Datamatrix can be used to point the customer at a web page that provides instructions,? care or re-order information.? In this way strong branding with rich information added is always part of the product.

It remains to be seen whether universal adoption of 2D barcodes is achieved by 2027 but we see no reason why factories should not move across to these formats now.? There is no downside, only benefit for the print on demand factory.

Go well, Andrew

Image Standardization: Challenges for POD

Samuel Brent, Director and CIO, Zensmart

Any manager of a print-on-demand firm will tell you about a persistent and increasingly annoying pain point: managing images for a single end product that come from diverse sources, each with its own format and size specifications. It’s a constant pain-point for good workflow.?

Print service providers (PSPs) face growing pressure to standardize these images to streamline production and maintain efficiency. The challenge becomes even more complex when orders from platforms like Gooten, Cloud Printer, and others enter the mix. These platforms often tailor output to their software capabilities, which may not align with the operational capabilities of their supplier printing facilities.

For a PSP, the ideal scenario involves receiving images that directly match their production capabilities without necessitating multiple product SKUs for slight size variations. However, the reality is often a mismatch between what order aggregators can deliver and what printing equipment can accommodate. This gap can lead to inefficiencies and production delays, as print providers juggle files that are not only varied in size but may also come in different orientations or with inappropriate bleed applied.

The modern printing environment doesn’t operate in isolation. With the rise of numerous web-to-print solutions (often used in parallel!) images and designs are churned out at high rates,? often lacking uniformity in size and specification. This results in pre-press drama where files from dozens of sources must be individually adjusted to fit a standard production workflow - essentially, a logistical puzzle that demands a sophisticated solution.

In ZenSmart we get around this issue by integrating image standardization capabilities directly within our imposition process, allowing files of any size, format, and orientation to be standardized during imposition, ensuring consistent output and seamless workflow integration. This capability is crucial, especially when dealing with multiple printing technologies or finishing processes that may require different image specifications.?

I’d love to take the credit for this important and apparently unique process but it was something we were forced into doing when working with some of our B2B2C clients in our early days. I can still recall the absolute junk they would be sent on a day to day basis and the difference our platform made to prepress efficiency once implemented.?

One cool benefit of us having added this capability - and coupling it with ZenSmart’s real-time imposition process - is that it means files are not just standardized in isolation; they are prepared in context, considering the specific printer or finishing line they will pass through. This is especially handy when a facility makes use of multiple print technologies such as DTG and DTF in the same plant. ZenSmart dynamically adjusts the image properties to meet the exact requirements of the production process at hand.

As aggregators and other order sources are increasingly inclined to say “yes” to anything their customers throw at them, it’s going to be equally increasingly important for PSPs to be able to do the same. The future of POD is therefore going to reside in embracing such dynamic, real-time solutions that can adapt to varying inputs and production needs without sacrificing speed or quality. As the industry evolves, the expectation is for even greater integration of these smart, adaptive processes across all platforms - not just in ZenSmart but throughout the print technology ecosystem. This progression will undoubtedly lead to more streamlined operations, reduced waste, and higher overall efficiency in print-on-demand services.