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Unclear or partially missing batch codes on packaging can lead to significant issues, ranging from traceability failures to regulatory non-compliance. At this point, understanding the causes of faded batch codes becomes one of the essential steps to mitigate these risks.
It may include assessing the entire aspects supporting your production, including the printing technology that you are currently using. This approach will help you determine whether the issue stems from minor factors or indicates the need to upgrade your printing system to more advanced technology.
Why Are Batch Codes Important in Manufacturing?
Batch codes are critical in manufacturing, serving vital roles for both manufacturers and consumers. But, why do they really matter and what makes them important?
Legal Compliance and Product Traceability
Batch codes consist of a unique identifier that can help manufacturers and consumers to track down and identify products’ expiration dates, batch sequences, and other crucial information. They are basically essential for tracking product distribution.
International regulatory bodies, such as ISO, have also mandated their inclusion. International regulatory bodies, such as ISO, have also mandated their inclusion for certain industries to include batch codes in their production. Noncompliance toward the regulation will lead to legal consequences.
Quality Assurance and Recall Readiness
Batch numbers are also useful for supply chain management. It lets manufacturers identify quality issues and quickly isolate affected batches from further distribution, thus managing product recalls can be much more efficient.
Most Common Causes of Faded Batch Codes
When producing batch codes, many manufacturers often deal with faded outputs, causing minor to major disruption to the business operation. Then, why does this happen? What are the most common causes of faded batch numbers?
Ink and Solvent Issues
If the ink level is running low, mostly it can lead to incomplete printing and missing codes. Additionally, if the ink is incompatible with the packaging material, it may smudge or fade over time.
Incorrect Printhead Settings
Incorrect printhead settings in continuous or thermal inkjet systems can result in incomplete transfers, resulting in faded parts of the codes. Likewise, when the printheads are worn out, it often leads to low print quality.
Environmental Factors (Humidity, Temperature, Dust)
Environmental factors like humidity, temperature, and dust are the other common causes of faded batch codes. Production environments with high temperature and humidity will affect the ink drying times, most likely causing smear and smudge.
Mismatched Ink with Substrate Type
Each type of ink has different compatibility with certain substrate types. If you are using unmatched ink types, it’s hard for them to bond properly with material surfaces.
How Surface Material Affects Batch Code Visibility
Surface material also becomes a determining factor that ensures batch code visibility. See how it works and influences the ink adhesion process below!
Porous vs Non-Porous Packaging
Porous packaging materials naturally absorb ink more effectively, making it easier for manufacturers to produce clear and durable results. But, in non-porous surfaces, inks tend to take a longer time to absorb, that’s why it requires specialised ink formulation to ensure clarity.
Coding on Films, Plastics, and Metals
Films, plastics, and metals are categorized as non-porous and smooth surfaces. Coding on these materials can be challenging, and if not executed properly, it often becomes one of the causes of faded batch codes.
These materials need specialized inks such as solvent-based, and advanced technology like thermal transfer. Together, they offer a reliable combination to support strong adhesion and fast drying systems in such challenging material types.
Read About: Cartridge Thermal Inkjet Printer: A Vital Component for High-Quality Printing
Equipment-Related Factors Behind Faded Printing
Oftentimes, factors behind faded batch codes lie in the printing equipment. This can include dirty printheads, misaligned nozzles, and outdated inkjet technology.
Dirty or Clogged Printheads
Dirty and clogged printheads can delay production flow, preventing ink from releasing evenly and thus resulting in faded characters or codes. Essentially, it will reduce the level of consistency and clarity of batch codes.
Misaligned Nozzles or Low Maintenance
Misaligned nozzles, combined with poor maintenance, are also major causes of faded batch codes. Once the nozzle is not aligned properly, the ink will miss the targeted area and create offside codes.
On top of that, when you are ignoring the importance of maintenance, dust will block the nozzles and cause mechanical wear. This not only affects print quality but also shortens equipment lifespan.
Outdated Inkjet or CIJ Technology
Older inkjet technology may have worn out equipment and not supported with the latest ink formulation. With outdated systems, the technology will have difficulties meeting the demands of a fast production line and high quality standards.
Preventative Measures to Ensure Durable Codes
Preventive measures help manufacturers combat the causes of faded batch codes before it leads to more serious problems. But, how to do that in an effective way to ensure durable codes? Follow our recommendation below!
Regular Printhead Cleaning and Calibration
Clean the printhead and other essential components, such as nozzles and sensors, to prevent dust and debris clogging and to keep ink constantly flowing.
Using the Right Ink for Each Substrate
Choose an ink type that is compatible with the substrate material. It will ensure solid ink adhesion and fast drying process, eliminating the potential cause of faint batch codes.
Environmental Control on the Production Floor
Pay attention to the production environment, make sure you are managing the temperatures and humidity properly to reduce the chance of ink drying issues.
Printer Setting Optimisation for Speed and Distance
Optimize your printer setting by adjusting the speed accordingly. If the speed is too low, it may cause smudging; if too high, the ink may spread unevenly and cause fading codes.
Signs You Need to Upgrade Your Coding System
Upgrading your coding technology into a more advanced one is necessary when certain signals indicate you to do so. Then, be sure you truly need it by checking on the following prominent signs.
Frequent Reprints or Customer Complaints
If you are experiencing frequent reprints and some customers are starting to complain, then it’s a clear sign to upgrade your printer in a timely manner.
It indicates that your printer technology is no longer able to maintain consistent quality which hugely affects traceability and recalls from customers.
High Scrap Rate Due to Poor Coding
High scrap rate due to poor coding quality can directly impact business profitability. This is often caused by printhead alignment issues and errors in the ongoing systems. Upgrading to a better system helps you maintain high print quality and code consistency.
Batch Code Not Meeting Regulatory Visibility Standard
Blurred batch codes mean the products are missing crucial information and also indicate that the product fails to meet the regulatory visibility standard.
It is frequently caused by outdated coding systems and for this reason, you need more reliable support that can deliver crisp batch code generation.
How Markcom Can Help You Avoid Faded Batch Codes
Markcom Global understands the importance of delivering clear and scannable batch codes not only for regulatory compliance, but also to safeguard your brand reputation. Not only for regulatory compliance, but to protect your brand reputation.
So, we are here with our latest marking and coding technology to fulfil the ever-evolving demands and to help you improve your batch coding generation. Discover and learn how our solution can simplify your printing process. Connect with us now!
References:
https://qoblex.com/blog/check-expiry-dates-from-batch-codes-key-industries/
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