Why are 2D barcodes becoming increasingly important in logistics and production?
In recent years, 2D barcodes have evolved from a niche technology into a central component of modern logistics and production processes. While simple linear barcodes used to suffice for displaying information, today's requirements for data density, traceability, and robustness are continuously increasing. 2D barcodes enable significantly more information to be stored in the smallest of spaces and reliably read even under challenging conditions.
Limitations of classic 1D barcodes
1D barcodes (e.g. EAN or Code 128) store information linearly. This leads to several structural limitations: the amount of data is limited, print quality must be high, and reliable scanning is hardly possible if the code is damaged. In addition, classic barcodes usually only carry an ID – additional information such as batch or serial number cannot be represented. They quickly reach their limits, especially in automated processes.
Requirements of Modern Logistics and Production Processes
Digital supply chains today require unique identification of components and pallets, serial numbers, batch and time stamps, and high scanning reliability – all seamlessly integrated into ERP, MES, and WMS systems. These requirements can be efficiently met with 2D barcodes and modern matrix coding.
What are 2D barcodes?
2D barcodes are two-dimensional codes that store information both horizontally and vertically. Unlike 1D codes, they use an area-based structure of dots, squares, or modules. This significantly increases data density. Typical stored content includes item and serial numbers, production data, URLs or reference numbers, as well as check digits and control characters.
Difference between 1D and 2D barcodes
2D barcodes are fundamentally different from classic barcodes:
- More information in a smaller space
- All-round legibility (not just horizontal)
- Integrated error correction
- Improved readability in case of damage or soiling
Wie funktioniert Matrix Codierung?
What is matrix encoding?
Matrix coding describes the technical principle where data is stored in a two-dimensional matrix of light and dark modules. Each module represents bits or groups of bits. Positioning elements ensure that scanners can align the code correctly. Matrix coding allows for high information density, different data formats, and redundant storage for error correction.
Data Matrix, QR Code & Co.
The best-known forms of matrix coding include:
- Data Matrix Code Especially common in industry and production
- QR Code: Frequently found in retail, marketing, and mobile applications
- Aztec code Compact, often in ticketing
- PDF417: Strictly speaking, a stack code, often used in government environments
In logistics and industry, 2D barcodes based on Data Matrix technology have become particularly established.
Data Matrix Code ECC200 The Data Matrix standard in use today is called ECC200. It utilises Reed-Solomon error correction and ensures readability even if up to 30 % elements of the code are damaged. ECC200 forms the basis for industrial use — and is a prerequisite for GS1-compliant labelling.
GS1 Data Matrix: In the logistics and pharmaceutical sectors, the GS1 Data Matrix code is the standard. It combines ECC200 technology with standardised GS1 Application Identifiers – for unique, internationally readable product identification at the individual item level. The technical basis is in the standard ISO/IEC 16022:2006 defined.
Comparison of common 2D code types
| 2D barcode type | Typical data volume | Correction | Advantages | Typical areas of application |
|---|---|---|---|---|
| QR code | very high (text, URLs, data) | High | widely used, quickly scannable, smartphone-capable | Marketing, Logistics, Tracking |
| Data Matrix (DMC) | High on a very small area | very high (ECC200) | Extremely compact, industrial-grade, DPM-capable | Production, Automotive, Medical Technology |
| PDF417 | very high (multi-line) | Middle | large datasets, structured | Identification, documents, transport |
| Aztec Code | High | High | no relaxation area needed, robust | Tickets, Transport, Authority Systems |
Note: Data Matrix and QR codes are used particularly for logistics and SAP processes.
Technically, how do 2D barcodes work?
Data structure and error correction
2D barcodes combine payload data with verification information. Algorithms for error correction (e.g., Reed-Solomon) can reconstruct data even if parts of the code are damaged or soiled. Matrix encoding enables partial reading of damaged areas, reliable decoding even with poor print quality, and stable operation in harsh environments.
Readability, robustness and direct part marking (DPM)
A key advantage of 2D barcodes is their high robustness. They can be scanned from different angles, captured using stationary or mobile scanners, and are omnidirectionally readable – exact alignment is not necessary.
Particularly in the metal industry and mechanical engineering, the so-called Direct Part Marking (DPM) plays a central role. The Data Matrix code is not printed onto a label, but applied directly to the metal surface of the component – by laser, needle etching, or chemical etching. The code is therefore permanently attached to the component, even if labels fall off or become illegible. This makes DPM the standard wherever parts need to be traceable for years: automotive, aerospace, medical technology.
Which scanners read 2D barcodes and Data Matrix codes?
Not every scanner is suitable for 2D barcodes. Classic laser scanners can only read 1D barcodes — imagers are required for Data Matrix codes and other 2D symbologies. These work with a camera instead of a laser beam and can read the complete 2D pattern of the code.
Stationary imagers
Stationary scanners are permanently mounted on conveyor belts, goods receiving gates, or assembly lines. They automatically capture 2D barcodes in motion – without manual scanning. Typical for fully automated logistics and production processes.
Mobile handheld scanner
Mobile hand scanners with 2D imagers are the standard for flexible warehouse processes, inventory management and goods recording. They read all common 1D and 2D symbologies – including Data Matrix, QR Code and PDF417. Robust industrial versions are designed for continuous operation in factory halls.
Industrial smartphones and MDE devices
Mobile Data Capture (MDE) devices and industrial smartphones combine scanner functionality with software integration in a single device. They read 2D barcodes and transfer the data directly into SAP, MES or WMS — without manual intermediate steps. They are now the most widely used class of scanners for processes in manufacturing, warehousing and on the shop floor.
Camera-based vision systems
For direct part marking (DPM) on metal, standard imagers are often insufficient. Camera-based vision systems with special lighting (polarising filters, ring lights) can also reliably read low-contrast, etched, or pin-punched Data Matrix codes on shiny surfaces. They are mainly used in automated quality inspection and in automotive manufacturing.
In der Logistik und der Produktion kommen 2D-Barcodes in folgenden Bereichen zum Einsatz: * **Lagerverwaltung:** Zur eindeutigen Identifizierung und Verfolgung von Artikeln, Paletten und Behältern im Lager. Sie ermöglichen eine schnellere und genauere Einlagerung, Auslagerung und Bestandsaufnahme. * **Kommissionierung:** Sie beschleunigen den Kommissionierprozess, indem sie dem Mitarbeiter direkt die Produktinformationen und Lagerorte anzeigen. * **Transport und Zustellung:** Für die Sendungsverfolgung und die Bestätigung der Zustellung. * **Produktionssteuerung und -überwachung:** Zur Nachverfolgung von Bauteilen und Produkten während des Fertigungsprozesses. Sie ermöglichen die Erfassung von Daten wie Produktionszeit, Chargennummer und Qualität. * **Qualitätssicherung:** Zur Dokumentation und Rückverfolgbarkeit von Produktdaten im Falle von Qualitätsmängeln oder Rückrufen. * **Arbeitszeiterfassung:** Zur Erfassung der Arbeitszeit von Mitarbeitern an verschiedenen Arbeitsplätzen in der Produktion. * **Bestellverwaltung:** Zur schnellen und fehlerfreien Zuordnung von eingehenden Bestellungen zu den entsprechenden Produkten. * **Werkerführung:** Zur Anzeige von Arbeitsanweisungen oder Informationen für den Produktionsmitarbeiter. 2D-Barcodes wie Data Matrix oder QR-Codes sind dabei von Vorteil, da sie mehr Informationen auf kleinem Raum speichern können als herkömmliche eindimensionale Barcodes und auch bei Beschädigung des Codes oft noch lesbar sind.
Logistics and warehousing
In logistics, 2D barcodes ensure unique identification of loading units, fast goods receipt and dispatch bookings, and transparent stock levels. Matrix coding allows all relevant information to be stored directly in the code without additional database queries – this speeds up every scanning process and reduces dependencies on network connections in the warehouse.
Production and traceability
In production, 2D barcodes are key to seamless traceability. Serial numbers at the individual part level, documentation of production steps, and direct linking with machine and process data – all of this can be mapped using Data Matrix codes. Matrix coding is now standard, particularly in the automotive or electronics sectors, often in combination with direct marking on components.
Quality Assurance
2D barcodes also play a central role in quality assurance. Inspection results can be directly assigned to a component, inspection plans are immediately called up via the code, and in the event of complaints, the complete traceability of every manufacturing step is ensured.
Advantages of mobile data capture
In connection with mobile devices, 2D barcodes reach their full potential. Thanks to omnidirectional readability, precise alignment is not necessary when scanning – this noticeably speeds up every work step. Manual inputs are drastically reduced, and the error rate decreases. Matrix coding is therefore particularly well suited for mobile scanners and industrial smartphones.
Practical example: Matrix codes with solutions from IGH Infotec AG
In IGH Infotec AG's customer projects, 2D barcodes are regularly used for the identification of components, containers and production orders. Through standardised matrix coding, data about the Mobile data capture solution Capture and seamlessly integrate the process into SAP.
Typical advantages:
- Real-time transparency of material flows
- Simplified traceability
- Measurable efficiency improvements
Conclusion: 2D barcodes as the key to transparent processes
2D barcodes have become an indispensable tool in logistics and production. Thanks to modern matrix coding, they offer high data density, robustness, and flexibility. Companies benefit from improved traceability, more efficient processes, and reliable mobile data capture. This makes 2D barcodes a central building block for transparent, digital value chains.
