Quick answer
To pass a customer's barcode quality check, print each code at least two printer dots wide per bar, keep heat, ribbon and printhead in good condition, and prove the result with a verifier. Linear codes are graded under ISO/IEC 15416 and 2D codes under ISO/IEC 15415, with ISO/IEC 15426 covering the verifiers themselves. Grades run from A (reads first time) down to F (scanners struggle), and many sites accept nothing below C.
Which standard applies to your label?
Look at the symbol, not the industry. A Code 128 carton code, an EAN on a retail pack and an ITF-14 on a shipper are linear, so ISO/IEC 15416 applies. A DataMatrix on a pharma carton, a QR code on a product and a PDF417 are 2D, so ISO/IEC 15415 applies. Many labels carry both, and a good verifier grades every code on the label separately.
In both cases the grade is built from about a dozen measured attributes, combined into one overall score on a 4.0 scale that maps to the letters A to F. Before you change printers, ask your customer which minimum grade they want. Grade C or better is a common rule in distribution and manufacturing, but your contract is what counts.
Pick the right resolution for your barcode size
Barcode size is given in mils, meaning thousandths of an inch, measured as the width of the narrowest bar, called the X-dimension. Label software such as BarTender always shows this value in the barcode properties. Because printer dots are round, a bar looks straighter when it is built from more than one row of dots. TSC's guidance is to make every bar at least two dots wide.
| Printer resolution | Size of one dot | Smallest X-dimension to use | Pick this if… |
|---|---|---|---|
| 203 dpi | 5 mil | 10 mil | your codes are normal carton, shipping or pallet size. |
| 300 dpi | 3.3 mil | 6.7 mil | you must fit DataMatrix, QR or dense Code 128 onto small labels. |
| 600 dpi | finer still | 3.4 mil | labels are tiny, such as on electronics components. |
Higher resolution does not raise the grade by itself. It lets you print smaller codes while keeping two dots per bar. A 10 mil code printed correctly at 203 dpi can grade just as well. For printers at each resolution, browse barcode printers, or for heavy compliance work see the Printronix T6000e, which offers 600 dpi on its 4-inch model.
Setting up a printer for good grades
- Set the X-dimension in your label software. Size the narrowest bar as a whole number of printer dots, at least two, for example 10 mil on a 203 dpi printer.
- Get the heat right. When the heat is too low, dots come out weak and contrast drops. When it is too high, or uneven across the head, some dots grow too big and bars spread into the gaps.
- Match the ribbon to the label. Thermal transfer melts wax or resin from the ribbon onto the label to form a durable dot, so a ribbon that suits the label face gives sharper edges. See thermal transfer ribbons and labels.
- Keep the media path square. Any skew or play in the drive tilts the bars, and an uneven feed makes the gaps vary along the length of the code.
- Look after the printhead. Clean it regularly, and replace it when it starts leaving voids. Genuine heads are in the TSC printhead and Printronix printhead collections.
Fixing a low grade: read the failing parameter
A verifier report does more than give a pass or fail. It lists the measured parameters, and the weakest one usually points straight to the cause.
| Weak parameter in the report | What it usually means | What to try first |
|---|---|---|
| Symbol contrast | Bars are not dark enough against the background | Raise the heat a step, and check the ribbon and label pairing |
| Defects or voids | Gaps inside bars where dots do not overlap | Clean the printhead, and replace it if the gaps stay in the same place |
| Modulation or edge contrast (ECmin) | Bars and spaces are uneven | Lower an over-high heat setting and check that the head temperature is even |
| Quiet zone (QZ) | Not enough clear space beside the code | Move the code away from the label edges and other print in your design |
| Axial or grid non-uniformity (2D) | The 2D grid is stretched or skewed | Check media feed and alignment, then recalibrate the printer |
| Unused error correction or fixed pattern damage (2D) | Parts of the symbol are damaged or missing | Look for printhead voids or ribbon wrinkles on that area |
Should you buy inline verification?
A handheld verifier only checks samples. Printronix ODV-2D sits on the printer and reads every 1D and 2D barcode on every label, whichever way it is turned on the label. It does two jobs: it verifies print quality against the ISO standards, and it validates that the printed data matches what the host sent. When a code falls below your threshold, it retracts the whole label, overstrikes it and prints a fresh one without anyone stepping in.
It pays off when one unreadable label can bring a chargeback, a returned shipment or a stopped assembly line. Vehicle makers, for example, set standard supplier label formats such as A5 or 6 x 8 inch and fine suppliers whose labels do not comply. See our automotive traceability and pharma labelling pages.
Your options here are the ready-built Printronix T8304 with 2D ODV barcode verifier, or a field kit for a printer you already own: the ODV field kit for 4-inch T6000e or the ODV field kit for 6-inch T8000. Prices are on the product pages, and we can quote for a whole line. Keep in mind that:
- Design codes at 10 mil or wider, as that is the narrowest X-dimension ODV-2D handles.
- Throughput depends on the validation options you choose and how many codes each label carries. Printronix lists 8 ips as the top print speed for the 4-inch T8000 ODV-2D printers.
- Printronix allows only ODV-2D Certified Partners to buy and install field kits, and a newly designed cutter is needed if you use a cutter with ODV-2D.
Getting the grading report
There are two ways to collect the data. In PrintNet Enterprise, a free download, start the AutoID Data Manager, run the job, stop collection and create a report, which is saved as a CSV file. In the report, a row such as "B1.1" means barcode 1 on label 1, and "L1.5" means label 1 had five barcodes read successfully. You can also open the ODV's own web page at its IP address, view the last failed image and use Export CSV. Keep these files, because they are your evidence if a customer disputes a shipment. See our 2D barcode verification page for typical set-ups.
Warranty and cover options
New printers ship with the standard manufacturer's warranty against manufacturing defects. Longer cover can only be bought at the time you buy the printer. You can choose a 1-year extended warranty, or a comprehensive warranty for 3 or 5 years, such as the 5-year Comprehensive Care Pack. There is no 1-year comprehensive option, and comprehensive cover can't be added later. The comprehensive warranty takes the place of the standard warranty, and both run together from the printer's invoice date. So a 5-year plan means 5 years in total, not 1 + 5. Once cover ends, ask us about an AMC.
FAQ
Which ISO standard covers a DataMatrix on a pharma carton?
ISO/IEC 15415, because DataMatrix is a 2D symbol. A linear Code 128 or EAN on the same carton is graded under ISO/IEC 15416.
What grade should my labels achieve?
Aim for whatever your customer's label specification sets. Grade C is a common minimum at distribution and manufacturing sites, and grade A means the code should scan on the first attempt.
Does a 300 dpi printer always give better grades?
No. Higher resolution lets you print smaller codes while keeping each bar at least two dots wide. A correctly sized 10 mil code at 203 dpi can grade just as well, as long as heat, ribbon, feed and printhead are right.
Can ODV-2D check linear barcodes as well as 2D codes?
Yes. It handles linear and 2D symbols alike, whether printed picket fence, ladder or at any other orthogonal angle.
What is the smallest barcode ODV-2D can grade?
10 mil is the limit for ODV-2D. ODV-1D works down to 6.6 mil because it uses a shorter focal distance.
How do I export a grading report from ODV-2D?
Use the AutoID Data Manager in PrintNet Enterprise to collect results and create a CSV report, or open the ODV web page by its IP address and use Export CSV.
Can I use a cutter on a printer with ODV-2D?
Yes, but ODV-2D needs a newly designed cutter option. The other 4-inch T8000 and T6000e field kit options work with it as usual.
Can I fit ODV-2D to a printer I already own?
Usually, yes. Printronix offers the ODV-2D field kit for any 4-inch T8000 or T6000e, our store also lists a kit for 6-inch T8000 printers, and installation is restricted to ODV-2D Certified Partners.
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