Bulletproof Your Product Marking: 5 Common Risks to Avoid

In modern manufacturing, a marking & codeing on packaging is more than just a label—it’s the heartbeat of your supply chain integrity. Yet, many producers treat coding as an afterthought, leading to a "utility trap" of expensive recalls, avoidable downtime, and tarnished brand trust.

 As GS1 standards tighten and line speeds accelerate, the margin for Mistake has disappeared. This guide reveals how to stop viewing coding as a "last-mile" necessity and start leveraging it as a strategic asset to eliminate waste and protect your bottom line.

Pitfall 1: The "One-Size-Fits-All" Trap in Technology Selection

The most fundamental Mistake begins before the printer even arrives at the factory: Selecting the wrong technology. Not all Batch Coding machines are created equal. A technology that works wonders on a small HDPE bottle will be entirely inappropriate for a large corrugated boxes.

The Reality of Choice

• Continuous Inkjet Printer (CIJ): Ideal for high-speed, non-contact printing on irregular surfaces. It is the workhorse of industries like beverage and cable manufacturing.
• Thermal Inkjet (TIJ): Best for high-resolution 2D codes and text on porous substrates like blister packaging. It offers "zero-maintenance" but has Higher running Cost.
• Drop on Demand (DOD): Designed specifically for large character coding. If you need to print high-contrast logos, batch details, or shipping info directly onto porous outer cartons, DOD is the most robust and cost-effective choice.
• Laser Marking: Provides permanent marks without consumables but requires higher upfront investment.

How to Avoid It: Conduct a thorough audit of your line speed, the size of the characters needed, and whether you are coding the primary product or the secondary outer packaging.

Pitfall 2: Ignoring the Science of Substrates (Ink Compatibility)

You can have the most advanced Continuous Inkjet Printer, but if the ink doesn’t "marry" the substrate, the code will fail.

The Porosity Factor

Manufacturers often fail to distinguish between porous surfaces (like cardboard cartons) and non-porous surfaces (like plastic films).

• DOD Printers use specialized inks designed to penetrate carton fibers for a smudge-proof finish.
• CIJ Printers use solvent-based inks that "bite" into plastics to ensure they don't rub off during transit.

How to Avoid It: Request a "Print Sample Test." Send your actual packaging material—especially your specific grade of carton board—to your inkjet machine manufacturer to test ink absorption and dry time.

Pitfall 3: The "Maintenance Myth" (Skipping Preventive Care)

A common refrain in factories is: "If it’s running, don't touch it." In industrial coding, this leads to clogged nozzles and "ghosting" or Chocking of ink filter which may lead to bigger losses.

The High Price of Neglect

Whether it’s a CIJ or a Drop on Demand (DOD) Printer, ignoring routine maintenance leads to ink buildup. The cost of one hour of downtime in a high-speed plant often exceeds the cost of an entire year’s worth of preventive care.

How to Avoid It:
1. Use printers with automated preventive maintenance alert.

2. Implement a daily startup/shutdown Scheduler feature

3. Yearly Annual Maintenance (AMC) let you schedule quarterly preventive maintenance audits to calibrate viscosity and check the condition of filters.

Pitfall 4: Overlooking the "Total Cost of Ownership" (TCO)

A common mistake is focusing solely on the "Sticker Price." For carton coding, many manufacturers use expensive labels when they could be using a Drop on Demand (DOD) Printer.

Direct Coding vs. Labelling

Direct coding onto cartons using DOD technology can reduce costs by up to 80% compared to traditional "Print and Apply" labelling systems, as it eliminates the cost of labels, manual labour and the downtime associated with mechanical setup.

Technology Comparison Table