Information Management: Image-based bar code reader achieves perfect read rates for 1D codes

A snack food manufacturer ran into problems when it tried using a laser-based bar code scanner to direct boxes to different shipping areas. After exchanging it with an image-based scanner, the company boosted its read rate from 30% to 100% while removing three full-time positions previously tasked with processing failed reads.

The old scanner was positioned 36 inches away and mounted at a height of 36 inches and aimed downward at an approximate 45-degree angle to the inspection surface. Variable box sizes made it necessary to position the laser-based scanner at an angle, and resulted in read rates of only 20% to 30%. Even with an employee to manually divert unread boxes, the company had to deal with the consequences of orders filled incorrectly, such as returned product that could not be resold.

The new image-based bar code reader can read any label at any orientation within its 12-inch by 12-inch field of view, improving the read rate to 100% even though it reads from the same location as the previous laser-based scanner. Image-based technology captures an image and uses algorithms to search for the code, identify the position and orientation of the code, and account for differences in material types and surfaces.

Mounting the new scanner in the same location and connecting it to the PLC took about six hours, and achieved a 100% read rate on day one. By removing the need for an employee to manually divert boxes during each of the operation’s three shifts, the new reader accounts for savings of approximately $100,000 annually. Preventing mistakes and returns is estimated to save another $150,000 per year.

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