2D codes are top of mind for virtually every company in the packaging industry. LEIBINGER, in a blog series, has detailed fresh angles and practical ideas that can be explored, along with emerging concepts designed to spark discussion and open exchange.

As manufacturers transition from 1D barcodes to GS1 2D codes, space on packaging and production line flexibility are becoming critical challenges. While the instinct is often to squeeze all data into a single complex code, a smarter, more innovative approach is emerging: splitting the code.

By dividing the data between a pre-printed fixed code and an inline variable code, manufacturers can achieve the perfect balance of compliance, marketing reach, and production efficiency.

The concept: Fixes vs. Variable

The strategy is simple but powerful. Instead of printing one massive 2D code containing every piece of data (GTIN, URL, Batch, Expiry, Weight, etc.) in real-time, you split the load:

1. The Anchor (Pre-Printed): A high-quality code containing all fixed data, such as the Global Trade Item Number (GTIN) and the GS1 Digital Link (URL). This is integrated into the packaging artwork.

2. The Variable (In-Line): A smaller, dynamic code printed during production containing only the variable data, such as Best Before Date (17) and Batch/Lot Number (10).

Modern vision systems and scanners are designed to read multiple codes within a defined field of view and seamlessly combine them into a single data set.

For this, multi-code settings are configured on the scanning systems. However, especially at the POS, whether and how both codes are actually captured in a single scan and processed correctly depends on the specific scanner model, configuration, and POS software. Therefore, it should be validated in the target setup. 

Visualizing the standard

To ensure that scanners and smartphones recognize the two codes as “one product,” they must be placed in close proximity. According to GS1 standards for associated marks, both symbols should fall within a specific field of view to be captured in a single scan.

Technical advantages

By offloading the complex, fixed data (like long URLs) to the pre-printing stage, the coding system on the production line only needs to print a small string of characters (Date/Batch). This simplifies the print job, allowing for faster processing and higher throughput. In term of speed difference, the change is simply impressive using CIJ technology.

In addition, smaller individual codes are easier to print with high precision than one large, dense code. Splitting the data reduces the risk of “dot placement errors” that can make a large 2D code unreadable, lowering rejection rates.

Packaging real estate is valuable, as well. By using the “split” method, you can fit the variable code into small open spaces on the label, provided it stays within the association zone of the fixed code.

Process and organizational benefits

Complexity is the enemy of uptime. Printing less data in real-time means the printer operates with greater margin for error and speed. Plus, marketing teams can finalize the fixed QR code (linking to the brand website) early in the design phase. The production team does not need to alter the artwork. When batch logic or date formats change, those are handled entirely by the printer settings.

There is also a lower TCO. Choosing a GS1 DataMatrix for the variable split significantly lowers TCO. It minimizes ink consumption per product compared to a similar QR code, while maintaining full supply chain compliance.

Systemic considerations

Modern GS1-compliant scanners and vision systems utilize “Image Association.” They capture the designated area, recognize multiple codes, and merge the data (GTIN + Batch + Date) into a single event automatically. This approach supports GS1 Digital Link and serialization efforts without requiring a complete packaging redesign every time a regulatory requirement shifts.

Conclusion

Splitting GS1 2D codes into fixed and variable parts is not just a workaround for limited space. It is a strategic advantage. It allows manufacturers to leverage the marketing power of pre-printed QR codes while maintaining the industrial efficiency of in-line DataMatrix printing.