Barcode Generation Guide: Everything Businesses Need to Know

What Are Barcodes?

Barcodes are machine-readable representations of data using parallel lines (1D barcodes) or patterns of squares (2D barcodes). They encode information that can be quickly scanned and processed by computers.

Brief History

• 1952: First barcode patent filed
• 1974: First UPC barcode scanned (Wrigley's gum)
• 1994: QR code invented in Japan
• Today: Over 5 billion barcode scans daily worldwide

How Barcodes Work

• Scanner emits light onto barcode
• Bars absorb or reflect the light differently
• Sensor detects pattern of reflections
• Decoder converts pattern to digital data
• System processes the information

Types of 1D Barcodes

UPC (Universal Product Code)

UPC-A (12 digits):

• Standard for North American retail
• Required for products sold in US/Canada
• Structure: Manufacturer ID + Product ID + Check digit

UPC-E (8 digits):

• Compressed version for small packages
• Derived from UPC-A

Example:

UPC-A: 012345678905
- 0: Number system
- 12345: Manufacturer code
- 67890: Product code
- 5: Check digit

EAN (European Article Number)

EAN-13 (13 digits):

• International standard
• Used worldwide (including US)
• Adds country code to UPC

EAN-8 (8 digits):

• Compact version
• For small products

Structure:

EAN-13: 5901234123457
- 590: Country code (Poland)
- 1234: Manufacturer
- 12345: Product
- 7: Check digit

Code 128

• High-density alphanumeric barcode
• Used in shipping and logistics
• Encodes all 128 ASCII characters
• Variable length

Use Cases:

• Shipping labels
• Inventory management
• Serial numbers
• Healthcare

Code 39

• Also known as Code 3 of 9
• Self-checking (no check digit needed)
• Alphanumeric + special characters
• Lower density than Code 128

Use Cases:

• Automotive industry
• Government/military
• General industrial

ITF-14

• Specifically for shipping containers
• 14 digits (GTIN-14)
• High tolerance to printing variations
• Used on corrugated cardboard

ISBN/ISSN

ISBN (Books):

• 13 digits (ISBN-13) or 10 digits (ISBN-10)
• Unique book identifier
• Published as EAN-13 barcode

ISSN (Periodicals):

• 8 digits
• Identifies newspapers and magazines
• Uses EAN-13 with special prefix

2D Barcode Types

QR Code (Quick Response)

Features:

• Stores up to 7,089 numeric characters
• Or 4,296 alphanumeric characters
• Error correction up to 30%
• Readable from any direction

Use Cases:

• Website URLs
• Contact information
• Wi-Fi credentials
• Payments
• Event tickets

Data Matrix

Features:

• Very small size possible
• High capacity
• Excellent error correction
• Often used in manufacturing

Use Cases:

• Electronic components
• Medical devices
• Aerospace parts
• Document management

PDF417

Features:

• Stacked linear barcode
• High capacity (1,850 characters)
• Used for large data sets

Use Cases:

• ID cards and driver's licenses
• Airline boarding passes
• Shipping labels

Choosing the Right Barcode

Decision Factors

Factor	Consideration
Data Type	Numeric only vs. alphanumeric
Data Amount	Characters needed
Size Available	Physical space on product
Environment	Indoor/outdoor, durability needs
Industry Standard	Required format compliance
Scanning Distance	Near vs. far reading

Barcode Selection Guide

Use Case	Recommended Barcode
Retail products (US)	UPC-A
Retail products (International)	EAN-13
Shipping boxes	ITF-14
Shipping labels	Code 128, GS1-128
Healthcare	Code 128, Data Matrix
URLs/Marketing	QR Code
Small electronics	Data Matrix
Books	ISBN (EAN-13)
ID cards	PDF417
Inventory tags	Code 39, Code 128

Getting Official Barcodes

For Retail Products

GS1 Membership (Required for major retailers):

• Join GS1 US (or your country's GS1)
• Obtain company prefix
• Assign product numbers
• Generate barcodes

Costs (GS1 US, 2025):

Barcode Capacity	Initial Fee	Annual Renewal
10 barcodes	$250	$50
100 barcodes	$750	$150
1,000 barcodes	$2,500	$500
10,000 barcodes	$6,500	$1,300
100,000 barcodes	$10,500	$2,100

For Internal Use Only

If barcodes are only for internal inventory (not retail):

• No GS1 membership needed
• Use Code 128 or Code 39
• Create your own numbering system
• Generate with free tools

Barcode Design Best Practices

Size Requirements

Minimum Sizes:

Barcode Type	Minimum Width	Minimum Height
UPC-A	1.175"	0.9"
EAN-13	1.5"	1"
Code 128	Varies by data	0.25" minimum
QR Code	0.4" × 0.4"	0.4" × 0.4"

Quiet Zones

White space around barcodes:

• 1D barcodes: 10× bar width on each side
• QR codes: 4 modules on each side
• Critical for reliable scanning

Color Considerations

Best Practices:

• Dark bars on light background
• Black on white is ideal
• High contrast required

Avoid:

• Red bars (invisible to red scanner light)
• Low contrast combinations
• Reflective/metallic surfaces

Acceptable Combinations:

Bar Color	Background	Scannable?
Black	White	Excellent
Dark Blue	White	Good
Dark Green	White	Good
Black	Light Yellow	Good
Red	White	Poor
Yellow	White	Very Poor

Placement Guidelines

• Flat surface (no curves)
• Away from edges and folds
• Consistent location per product type
• Accessible for scanning angle

Implementing Barcodes in Your Business

Hardware Needed

Barcode Scanners:

Type	Price Range	Best For
Wired USB	$20-100	Desktop checkout
Wireless	$50-200	Warehouse
Mobile App	Free-$10/mo	Small operations
Fixed-Mount	$200-1,000	Production lines

Barcode Printers:

Type	Price Range	Volume
Desktop Thermal	$200-500	Low-Medium
Industrial	$1,000-3,000	High
Mobile	$300-800	Field use

Software Integration

Inventory Management:

• Track stock levels automatically
• Receive/ship with scanning
• Generate reports

Point of Sale:

• Fast checkout
• Price lookup
• Sales tracking

Asset Tracking:

• Equipment management
• Maintenance scheduling
• Location tracking

Common Barcode Problems and Solutions

Scanning Failures

Problem	Cause	Solution
No read	Damaged barcode	Reprint barcode
Partial read	Quiet zone issue	Add white space
Slow read	Low contrast	Use darker bars
Misread	Printing error	Verify and reprint

Quality Issues

Print Quality Verification:

• Use barcode verifiers
• Check regularly
• Maintain printers

Common Defects:

• Spots or voids in bars
• Ink spread (bars too wide)
• Low density printing
• Skew or distortion

Using the Barcode Generator

ToolPop's free Barcode Generator helps you:

• Create multiple barcode types (UPC, EAN, Code 128, etc.)
• Customize size and format
• Download high-resolution images
• Generate for testing purposes

Tips for Best Results

• Enter data accurately
• Choose appropriate type
• Verify output before printing
• Test scan before production

Future of Barcodes

Emerging Technologies

GS1 Digital Link:

• Web-enabled barcodes
• Connect physical products to digital content
• Single code for multiple purposes

RFID Integration:

• Combined barcode/RFID tags
• Enables line-of-sight and wireless scanning
• Enhanced tracking capabilities

Augmented Reality:

• Scan products for AR experiences
• Interactive product information
• Enhanced customer engagement

Conclusion

Barcodes are fundamental to modern business operations:

• Choose the right type for your specific use case
• Follow standards for retail and supply chain
• Design properly for reliable scanning
• Implement systematically for maximum benefit
• Maintain quality for consistent results

Use ToolPop's free Barcode Generator to create barcodes for testing, internal use, or prototyping. For retail products, obtain official numbers through GS1 membership.