Technology White Paper

The Most Common Causes

of Unreadable Barcodes

Understanding, Preventing, and

Resolving Decoding Failures
Technology White Paper

The Most Common Causes of Unreadable Barcodes

Item identification and data acquisition through barcodes is critical to the function of automated operations, from ensuring that the correct
components are used in the assembly of a smart phone to recording accurate patient data for samples in a laboratory. When poorly-marked
or damaged barcodes result in “no-reads” or failures, loss of data can have disastrous effects on product integrity and corporate reputation
– not to mention potential legal implications and serious risks to consumer welfare. Understanding the root cause of unreadable barcodes
and using technology appropriately to prepare for or resolve these issues is simple to do and it can mean the difference between success
and failure in automation. This white paper describes potential solutions for the most common causes of unreadable barcodes, including:

- Low Contrast
- Quiet Zone Violations
- Improper Reading Position
- Print or Mark Inconsistency
- Damage or Distortion

Microscan Systems, Inc.

The readability of barcodes is determined by how well a barcode

reader can decode the data stored in the symbol. Barcode read-
Low Contrast
ability is impacted by a number of technical and environmental In order to extract data from the elements (1D bars or 2D cells)
factors. Although a barcode may appear to have no noticeable of a barcode, a barcode reader must be able to differentiate be-
flaws to the human eye, subtle inconsistencies in the code, tween the light and dark elements of the symbol. Both element
substrate, or even the positioning of the code in relation to the types are essential for proper decoding, enabling a barcode
reader may result in no-reads. For seemingly high-quality codes, reader to obtain the precise patterns of barcode elements that
it is a common misconception that no-read results are due to represent encoded data in the symbol. Depending on the method
obscure or undetectable barcode characteristics that the reader used to apply a barcode (whether printed by ink or marked by
is simply unable to address, causing frustration for operators abrading a material’s surface in the case of direct part marks),
whose intention is to maximize the efficiency of an automated as well as what kind of material is used, light or dark elements
barcode reading process. However, the root cause of unread- may alternately manifest as either the markings on a surface
able barcodes is often one of a handful of common problems (the code itself), or the background (substrate material) onto
that can easily be solved with simple adjustments to either the which the marks are applied. If there is not enough contrast
barcode or the technology used to decode it. between these two barcode elements, a barcode reader may be
unable to distinguish the barcode from its substrate, and the
result may be a no-read.

Figure 2: Dark barcodes printed on dark backgrounds (like this 1D

barcode on cardboard), or light symbols marked on light or reflective
Figure 1: To the human eye, this Data Matrix symbol may appear to be materials (like this 2D Data Matrix on metal), can cause no read results
flawless. However, this symbol does not meet barcode quality requirements due to poor contrast between light and dark symbol elements.
for some industries and may be unreadable by certain barcode readers.
Another example of low contrast is lack of uniformity of the light
Understanding the primary reasons for decoding failures can and dark barcode elements. This can be affected by the con-
save operators valuable time and effort when diagnosing reading sistency of the marking or printing method in producing light or
issues. It also allows businesses to safeguard their processes dark elements evenly across the code, the amount of variation or
and profitability by equipping their operations with the optimal noise in the background or substrate, or lighting conditions that
tools and conditions for preventing data loss and process fail- cause reflections or shadows on the substrate. These uniformity
ures further down the line. The most common causes of unread- issues can make a barcode reader blind to the barcode. In cases
able barcodes are low contrast, quiet zone violations, improper where the barcode can still be decoded, low contrast or non-
reading position, print or mark inconsistency, and damage or uniformity of barcode elements can dramatically slow a reader’s
distortion.

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decode time and can limit the distance at which a barcode can
be read.

Figure 6: The effects of proper lighting on etched metal.

Other factors to consider when addressing low contrast codes

are the type of barcode and the type of reader being used in the
application. Linear (1D) barcodes such as UPC/EAN and stacked
symbols such as PDF417 must be distinguishable across the
Figure 3: A series of Data Matrix symbols directly marked on metal vary in
readability due to noisy background caused by the inconsistent substrate.
entire length of the symbol to capture all critical elements (in
this case, bars) for decoding. If any of the bars of the barcode
are obscured due to low contrast, the result can be a no-read for
the entire code. Since linear barcodes are typically longer, good
Possible Solutions contrast must be obtained for a large surface area, as opposed
to 2D symbols such as Data Matrix and QR Code, which are typi-
Ensuring distinct and uniform barcode elements is the first step cally more compact.
to preventing unreadable codes due to low contrast. In cases
where the printing or marking method is causing inconsisten-
cies in barcode elements, it is important to adjust the printer or
marking equipment to ensure that ink is applied evenly across
the elements of the symbol, or that the marking equipment is
abrading the substrate with uniform pressure.

Figure 7: The scan line of a laser barcode scanner must cross all bars in a
Figure 4: Poor distribution of ink on this test tube barcode label has linear barcode in order to ensure readability.
resulted in some white spots within the bar elements, which may lead to
readability issues. Laser barcode scanners (used exclusively for reading 1D codes)
interpret a wave pattern created when the laser light bounces
It is often the substrate onto which the code is applied that
from the symbol back to the scanner. The reflections from the
most dramatically affects the contrast of barcode elements. To
light and dark bars are processed and interpreted as characters.
deal with uneven, noisy, or highly-reflective substrates, or poor
Linear barcodes typically require much higher contrast than 2D
distinction between the substrate and the mark due to shadows
symbols – usually 80% or higher contrast between light and dark
or mark depth, the critical component is lighting. Lighting equip-
elements to acquire a uniform wave pattern. No-reads will occur
ment for barcode reading is designed in a variety of geometries,
when there is too little contrast between a code’s light and dark
tailored to produce the most uniform and highest-contrast im-
elements. In comparison, 2D imagers use cameras to capture
ages of barcodes marked by a number of means on a range of
images of 1D or 2D codes and require as little as 20% contrast
substrates. While diffused lighting may help to illuminate printed
between light and dark elements. For these reasons, using 2D
barcodes on glossy, flat surfaces, dark field lighting can apply
symbols instead of 1D barcodes and, subsequently, 2D barcode
low-angle beams of light to targeted regions of a substrate, en-
imagers in barcode reading may decrease the possibility of un-
hancing the readability of embossed or engraved barcodes. readable codes due to low contrast.

Figure 8: Linear (1D) barcode scanners interpret reflections of laser light

as wave patterns representing the light and dark elements of a symbol.
Figure 5: The effects of proper lighting on a glossy label. These wave patterns illustrate the difference between high- and low-con-
trast barcodes.

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Quiet Zone Violations When background noise or unexpected marks and debris enter
the quiet zone, no-reads may be due to errors in the printing or
The quiet zone is the area surrounding a barcode or 2D symbol marking method. Care should be taken to ensure that printing
that must be kept free of text, marks, or obstacles (also referred and marking equipment is working as expected to avoid unin-
to as the “no-print zone”). All barcode readers have tolerances tended marks that may cause quiet zone violations. Additional
for minimum allowable quiet zone size. This space provides sep- lighting techniques can also be employed in situations where the
aration from surrounding marks, allowing the reader to “see” the quiet zone contains noise caused by reflections or shadows on
code in its entirety. In 1D barcodes, the quiet zone lies to the left an uneven substrate.
and right ends of the barcode. As a general rule, the quiet zone
should be a minimum of 10 times the width of the narrowest bar When the area available to print or mark a barcode is limited by
of the 1D barcode. In 2D symbols, the quiet zone is the space the overall surface area on a part, such as a densely-populated
surrounding the entire symbol. Quiet zone requirements for 2D PCB or a tiny electrical component or medical device, quiet zone
symbols are prescribed by the Association for Automatic Identifi- real estate may be difficult to come by. If quiet zones must be
cation and Mobility (AIM), which specifies at least a one-element constrained, an operator may choose to employ a barcode reader
(or cell) width on each side of the symbol. For best results with with sophisticated decoding algorithms that accommodate minor
large 2D codes, it is typically recommended that the quiet zone quiet zone infringements. Some high-performance barcode read-
be 10% of the symbol height or width, whichever is smaller. ing technologies are capable of ensuring good reads even when
the quiet zone is narrower than the prescribed minimums for 1D
and 2D codes.

Figure 9: The quiet zone must be at least 10 times the width of the nar-
rowest bar on either side of a linear (1D) barcode, or the width of one
element on each side of a 2D symbol.

A reader may be unable to decode a symbol if text or other mark-

ings bleed into the symbol’s quiet zone. Or, quiet zone violations
may yield inaccurately decoded data strings if the reader inter-
prets non-symbol elements as part of the overall symbol.

Possible Solutions
Figure 11: A high-performance imager uses special algorithms to read
Quiet zone violations are possibly the most easily-detected and codes with limited quiet zones, such as a Data Matrix on this crowded PCB.
resolvable causes of unreadable barcodes. This is because
quiet zone violations are often due to a simple lack of planning Improper Reading Position
for the inclusion of space around a printed or marked barcode or
symbol. All that is needed to solve basic quiet zone violations is In some cases, a readable barcode may receive a no-read result,
to adjust the printing or marking method – or the substrate – to not because of its print or mark quality, but due to the physical
accommodate the space requirements for minimum quiet zone. position of the barcode reader relative to the code. Depending
As much space as possible should be devoted to the quiet zone on the technology, barcode readers may have unique require-
to reduce the chance of reading errors. There is no maximum ments for reading codes at specific focal distances, angles, or
specification for quiet zone width, so there is no reason to limit orientations (in the case of tilted or rotated codes). Most bar-
this space if not required. code readers’ focal distances are limited by their internal optics.
The barcode reader’s depth of field (the area from the closest
possible read distance to the farthest possible read distance)
determines exactly how near or far a reader can be positioned in
relation to a barcode to ensure reliable decoding.

Figure 10: As much space as possible should be provided for the quiet
zone around a barcode, free from print and other elements. Figure 12: The specifications of a given barcode reader determine exactly
how far away a reader can be positioned from a code in order to capture
the code in focus within its read range.

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The angle at which a barcode reader scans or captures images perpendicular to a barcode. Barcode imagers are also able to
of a symbol can also have an impact on its read performance. read barcodes in any orientation, and therefore do not need to
Mounting a barcode reader perpendicular to a code may cause be mounted at the same rotation as the code to ensure a reli-
specular reflection – the direct return of laser light (in the case able decode. In fact, barcode imagers may be the optimal choice
of laser barcode scanners) or integrated LED lighting (in imag- in applications where codes are hand-applied to parts, or where
ers) from the code or substrate – effectively “blinding” the parts are fed into equipment in unpredictable orientations, to
reader. When this happens, a barcode reader may be unable to ensure codes are read regardless of rotation or position.
capture the entire code in high enough contrast, causing a no-
read result even if the code is flawless.

Figure 15: Barcode imagers are capable of reading barcodes and symbols
in any orientation.

For applications with space constraints and geometric challeng-

es, options for mounting barcode readers within equipment may
Figure 13: Barcode readers should typically be mounted at an angle to be severely limited. Right-angle mirrors can be incorporated in
barcodes to avoid direct reflections of light back to the reader. these cases to allow readers to “see” barcodes even when they
are not positioned in direct view of the barcode. Using right-angle
No-read results can also occur if a barcode is presented to a mirrors, an operator can aim a scanner’s laser to a code and
barcode reader at a particular rotation or orientation that is not back, or reflect barcode images back to an imager, enabling good
accommodated by the reader’s technology. Laser barcode scan- reads even from challenging positions. Many barcode readers
ners, for instance, must always be oriented in such a way that contain special algorithms for decoding mirrored images, which
the laser’s scan line is perpendicular to the bars of the barcode. may be necessary for decoding barcodes that appear “flipped.”
If this orientation deviates such that the scan line does not
cross all elements (bars) of the barcode, the barcode will not be
properly decoded.

Possible Solutions

It is important to refer to a barcode reader’s technical speci-

fications to ensure that the limitations and requirements
regarding the reader’s position in relation to a code are taken
into consideration when mounting a reader into equipment or
presenting a code to a reader. If application requirements are Figure 16: When using right-angle mirrors, it is important to employ a
barcode reader capable of reading both regular and mirrored images.
challenging, it may be appropriate to employ a barcode reader
that is better-suited to accommodating unpredictable barcode
distances, angles, and orientations. For instance, barcode read- Print or Mark Inconsistency
ers with built-in autofocus are able to decode symbols reliably
at variable distances within their depths of field without manual Variations in the printing or marking method, such as poor dis-
focal adjustment. Even more capable are liquid lens autofocus tribution of ink for printed codes or uneven pressure in surface
barcode readers, whose lenses – containing actual liquid that abrasion during the direct part marking process, can be an
is manipulated for increased or reduced curvature by electrical underlying contributor to many readability issues. When printing
signals – are able to adjust to practically infinite focal distances, and marking equipment do not produce and apply codes as ex-
allowing for the greatest possible flexibility in read distances pected, problems such as low contrast and quiet zone violations
from the barcode. may result. There are several other causes of poor barcode qual-
ity or inconsistency that can cause trouble for barcode readers
that are configured to “expect” symbols of a particular shape,
skew, and uniformity:

Axial Non-Uniformity – The amount of deviation

along a symbol’s major axes. In this example, the
Figure 14: Liquid reacts to electrostatic pressure to produce the appropri-
ate lens curvature for a liquid lens barcode reader. symbol’s Y-axis is clearly greater than its X-axis.
This inconsistency of X- and Y-dimensions typically
Applications with varying read angles and specific mounting indicates unexpected movement of the substrate
requirements may benefit more from barcode imagers than laser as the barcode is applied by a printer or direct part
barcode scanners. Imagers use built-in cameras to capture marking device.
images of codes rather than relying on reflective laser beams,
so their ability to read a barcode is less likely to be obstructed
by specular reflections when the imager is mounted directly

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(DOD), or High Resolution Case Coding, care should be taken to

Contrast – The difference between the light and
verify the correct distance of the printhead, clean and unblocked
dark elements of a barcode, or between the code
printheads and nozzles, and ensure the correct speed and setup
and its quiet zone and other perimeter elements. In
of the printing process. If barcodes are produced by laser cod-
this example, the dark elements (etch marks) and
ing, correct focal distance and a continuous power supply to the
the light elements (the substrate) are too close in
equipment ensures high-contrast printing without losses in print
value due to low pressure in the marking process,
distribution or speed. Thermal Transfer (TTO) and Direct Thermal
undermining readability.
(DTO) methods use wax or resin ribbon (or other thermal media)
to apply barcodes to the substrate, so it is important to avoid rib-
Grid Non-Uniformity – The amount of deviation in a bon wrinkles, to verify correct insertion of the ribbon into equip-
barcode’s bar or cell elements from the ideal grid of ment, to use high-quality ribbon or other thermal material, and
a theoretical “perfect symbol.” Printing or marking to use quality printheads and platen rollers for evenly-applied
errors that cause grid non-uniformity (usually due barcodes without missing elements.
to unexpected movement of the substrate during
code application) will produce a code that appears
skewed or distorted, which may be unreadable by
standard decoding devices.

Modulation – The uniformity of light and dark ele-

ments of a barcode. In these examples, the dark
elements of the symbol do not have a consistent
value. This issue, like low contrast, is often due to
inconsistent distribution of ink for printed codes or
Figure 17: Ink-based case coding equipment prints linear barcodes
uneven abrasion for direct part marks. directly onto cardboard packaging. Movement of products during printing
and variations in product speed can greatly impact the quality of these
Print Growth – The deviation (larger or smaller) of barcodes at the time they are applied.
symbol element size from the intended or theoreti-
cally “perfect” element size for a particular symbol. The key to producing high-quality marks by direct abrasion is
When a symbol is printed, the ink may “bleed” consistent pressure of the abrading component against the sub-
when it comes in contact with the substrate, strate. Direct part marking is accomplished by a number of meth-
causing an overprint. If there is not enough ink or ods, such as electromechanical etch, laser etch, chemical etch
pressure applied by printing or marking equipment, (methods in which codes are “scratched” into the substrate) and
the result may be an underprint. dot peen (a percussive method in which the symbol is hammered
into the substrate with a metal stylus). It is important to verify
the quality of the material used to create the abrasion (laser,
Quiet Zone – The area surrounding a barcode that
chemical, or metal stylus) and the amount of power supplied
must be kept free of text, marks, or other obsta-
to the marking equipment to ensure that barcodes are applied
cles. In this example, a barcode has been printed
uniformly and with consistent pressure.
outside of the designated quiet zone area and is
overlapping with other elements on the substrate.
This could be due to misalignment or movement of
the substrate in relation to the printing equipment.

Reflectance – The reflectance of light from a sym-

bol’s light or dark elements that allow a barcode
reader to distinguish symbol elements from the
background (substrate material) and to distinguish
light elements from dark elements. Low reflec-
tance, as illustrated by this example, may increase
the probability that a symbol element may be incor-
Figure 18: A dot peen direct part marking system uses a metal stylus to
rectly identified as light or dark, causing a no-read pound elements into a metal surface. It is important to ensure mark pres-
result as the barcode reader attempts to interpret sure is consistent when marking to avoid uneven or low-contrast symbols.
incorrect element patterns. Low reflectance may be
caused by inconsistent print distribution or marking In addition to – and sometimes in lieu of – devoting excessive
pressure by equipment. time and effort to maintaining perfectly-functioning printing and
marking equipment, operators may choose to safeguard their op-
Possible Solutions erations against print or mark inconsistency by using more pow-
erful barcode readers. Barcode readers engineered with sophis-
It is important to inspect and maintain printing and marking ticated decoding algorithms are able to read codes with a wide
equipment regularly to ensure that high-quality, consistent variety of quality issues, such as shape, skew, and uniformity
barcodes are produced and applied to parts to avoid no-reads. deviations from the characteristics of the theoretically “perfect”
When printing barcodes using ink-based methods such as Con- barcode. Of course, even with high-performance readers, regular
tinuous Inkjet (CIJ), Thermal Inkjet (TIJ), Piezo Drop on Demand maintenance of equipment should not be avoided.

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Damage or Distortion barcode elements from the view of the reader – unintended
material abrasions, marks, surface stains, or excess material
While printing and marking inconsistencies pose their own (debris or even mounting fixtures) – can cause no-read results.
decoding challenges, the risk of no-reads can persist even with The images below are just a few examples of barcode damage.
high-quality barcodes. Barcode quality may degrade as parts
move through operations and are exposed to various environ-
mental factors. Harsh conditions may cause enough damage
or distortion to the barcode or substrate to render even the
best-quality barcodes unreadable. Damage can range from minor
scratches, partial obstruction of the code by blotches, stains, or
even debris causing torn or entirely missing barcodes. Figure 21: Examples of barcode damage including material obstructions,
scratches, and marks.
Distortion – Several environmental factors can contribute to bar-
code distortion in terms of shape, contrast, element uniformity, Possible Solutions
and substrate integrity. For example, temperature changes in a
production environment can cause condensation to form on a Once a barcode is released into a production environment, con-
code, blotching ink or distorting the substrate to a point at which sistent barcode quality can be difficult to maintain. In operations
the barcode’s elements are no longer discernable to the reader. that use barcodes to track and identify items even after they
have been transported between facilities or sold to customers
to be read by new barcode reading equipment, the means for
preventing or resolving barcode damage and distortion is very
limited. Some preparation can be done at the outset of code pro-
duction to limit future damage – such as choosing a substrate
resistant to harsh environmental conditions, printing or marking
barcodes so they can withstand any anticipated environmental
factors, and maintaining a production environment as free from
Figure 19: Environmental conditions have damaged this linear code to potential sources of damage as possible.
the point where significant portions of the bars have been blotched out,
rendering it unreadable by standard equipment.

Fixed Pattern Damage – Damage to patterns of barcode ele-

ments, which the reader interprets as data, can significantly
undermine readability. In 2D symbols such as this Data Matrix,
Fixed Pattern Damage refers to missing elements in the sym-
bol’s “finder pattern” (the outermost rows and columns of the
symbol), which includes the “L-pattern” (the solid left and bot-
tom rows of symbol elements) and “clock pattern” (the elements
on the symbol edges opposite the “L”). These patterns allow the
barcode reader to interpret the barcode orientation and number
of rows and columns appropriately for decoding. Obstruction
of these symbol patterns by scratches, stains, debris, or other
material can render the barcode unreadable.
Figure 22: Barcodes are read in a dusty food packaging facility, where
extra care must be taken to ensure both barcodes and barcode readers
withstand environmental conditions.

Certain code types provide the option of encoding special data to

assist in the decode process even when the code is damaged.
Data Matrix symbols offer multiple levels of error checking and
correcting (ECC, which also stands for “error-correcting code”),
the standard being ECC-200, which is based on Reed-Solomon
error correction principles. Reed-Solomon error correction allows
as much as 50% of the Data Matrix to be damaged without
rendering it unreadable. Error correction is encoded as elements
in the data storage area of the code, increasing data recover-
Figure 20: The critical elements of a Data Matrix symbol, including the ability by presenting symbol data to the reader in multiple ways.
L-pattern, clock pattern, and data storage area. Readability of the symbol
is dependent capturing all critical elements clearly enough for the barcode Almost all applications have accepted ECC-200 Reed-Solomon
reader to interpret data. error correction as the standard, as it is the best error correction
methodology available for the Data Matrix code type.
Other Damage – The environmental conditions to which a bar-
code may be exposed are limitless, and so are the ways in which
a barcode can incur damage. Any kind of damage that obstructs

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above, but also to grade codes against specific thresholds of ac-

ceptable quality for each readability parameter. This is especially
important for identifying no-read issues with codes containing
multiple errors - such as overprinting in addition to fixed pattern
damage. Verification ensures not only that codes will be readable
at the time they are presented to a barcode reader, but it can
Figure 23: The Reed-Solomon method of error correction enables also be used to monitor and predict the degradation of codes
decoding even if as much as 50% of the Data Matrix is obscured. Here, over time, even when these degradations are not discernible to
ECC 200 symbol is reliably decoded despite partial obstruction. the human eye. Some verification equipment can be programmed
to alert operators when barcodes fall below a threshold of ac-
Although as much care as possible should be taken to prevent ceptable quality so that it is evident when a printer, a piece of
no-reads due to barcode damage, it is often preferable to focus marking equipment, or a marking process begins to fail. Barcode
on the capabilities of the barcode reader rather than on the verification equipment is a company’s greatest defense against
barcode itself. For the most challenging applications, in which unreadable barcodes, but it can be more expensive and difficult
barcode damage or distortion is unpredictable, high-performance to install than high-performance barcode readers. When the pri-
readers are usually installed from the outset. Barcode readers mary concern is simply to read barcodes (and not ensure 100%
engineered with the most powerful decoding algorithms feature quality), advanced barcode readers may be the best choice.
advanced symbol location, gradient or reflectivity analysis, and
the ability to grid-map the symbol image to produce an ideal,
reliably-decodable symbol during processing. Barcode readers
like these may also offer symbol reconstruction technology – a
method by which the reader uses an algorithm to piece together
discontinuous symbol data from multiple scan lines. In the case
of partially-obscured or rotated symbols, the algorithm combines
incomplete code segments into the equivalent of a single, com-
plete scan line, which can then be decoded by the reader.

Figure 25: Machine vision software is used to verify a symbol against the
ISO 15416 standard for barcode quality and monitor fluctuations in code
quality over time.

Conclusion
While unreadable barcodes can be highly disruptive to a com-
pany’s operations, it is often quite simple to establish a defense
against poor quality barcodes and the no-reads that result. The
causes of unreadable barcodes commonly manifest as a limited
Figure 24: Symbol reconstruction algorithms create a single readable scan set of fairly straightforward issues, including low contrast, quiet
line from multiple incomplete pieces of a damaged or distorted barcode. zone violations, improper reading position, print or mark incon-
sistency, and damage or distortion. Once the cause of barcode
unreadability is defined, it can be addressed by taking simple
Advanced Barcode Quality Assurance preventive measures. In many cases, barcode printing and mark-
ing methods can be optimized to ensure that high-quality codes
When creating and reading high-quality barcodes, the best are produced from the beginning. But when grade-A barcodes are
defense is a great offense. For applications in which code quality a luxury and reliable barcode reading is the priority, the aggres-
is of the utmost importance, or in industries where codes are sive decoding capabilities of high-performance barcode scan-
required by federal mandate or customer contract to meet spe- ners and imagers ensure good reads every time and protect a
cific barcode quality standards (such as those proposed by AIM, company’s most valuable time and data.
ANSI, GS1, ISO, and other standards organizations), barcode
verification equipment may be installed to detect the causes
of unreadable barcodes before they result in errors throughout
operations. Barcode verification systems including verifiers, ma-
chine vision cameras, and verification software are engineered
not only to identify all the common readability issues described w w w . m i c r o s c a n . c o m

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