GS1 Sunrise 2027: The Shift to 2D Barcodes & the Impact on Case Coding

What is the GS1 Sunrise 2027 Initiative?

In an era defined by digital transformation and an ever-changing supply chain landscape, manufacturers are continuously evolving to meet demands for efficiency, accuracy, and traceability. One of the most significant shifts on the horizon is the GS1 Sunrise 2027 initiative. By the end of 2027, this initiative mandates the transition from traditional 1D barcodes (linear barcodes including EAN and UPC) to 2D barcodes (such as Data Matrix and QR codes) on all products.

The change is intended to enhance product information storage, increase scanning accuracy, and streamline logistics processes. The move to 2D barcodes will require manufacturers to make operational changes, especially in their case coding and box printing equipment. This white paper discusses the specific impact on secondary packaging and how manufacturers can prepare for the upcoming transition.

What Benefits does a 2D Barcode Provide?

Enhanced Information Density and Functionality

Existing Linear 1D barcodes, typically store minimal information, often limited to a product identifier like the Global Trade Item Number (GTIN). In contrast, 2D barcodes can store much more data. A single 2D barcode can contain:

• Product identifiers
• Lot numbers
• Expiration dates
• Batch numbers
• Serialization data
• Bill of materials
• Ingredient and allergen information

This increase in information density supports better traceability, which is essential for industries such as food and beverage, pharmaceuticals, and other consumer packaged goods (GPGs). By scanning a 2D barcode, distributors and retailers can access critical data used to improve:

• Inventory Controls
• Recall Management
• Anti-Counterfeiting
• Farm-To-Table Produce Traceability
• Quality Assurance
• In-Process and Production Workflows

Empowered Customer Experience

Sunrise 2027 will bring significant benefits to consumers and end-users by enhancing product transparency, safety, and overall shopping experience The GS1 Digital Link format allows a singe 2D barcode to act as a consumer-facing web-based URL allowing customer to scan at point-of-sale, accessing more detailed information about the products. Consumers can now view details like ingredients, allergens, country of origin, and product data, all with a simple scan using their smartphones. This added level of transparency will empower end-users to make informed purchasing decisions, ultimately improving consumer confidence and satisfaction.

Boost Supply Chain Automation

Data-rich 2D barcodes enable machines and automated systems to quickly identify, sort, and track products with minimal human input. Systems like Warehouse Management (WMS) and Automated Storage and Retrieval (ASRS) use this data to automate key tasks like inventory control, order fulfillment, and palletizing. This automation streamlines supply chain operations, increases efficiency, and reduces labor costs. Manufacturers that adopt 2D barcode technology early will future-proof their operations, ensuring they stay compatible with advancements in automation, robotics, and Industry 4.0 connectivity, while boosting throughput and accuracy.

How does Sunrise 2027 Impact Secondary Packaging?

In short, Sunrise 2027 will require manufacturers to shift to real-time, on-demand case coding and labeling for their distribution cartons and overpack boxes.

Currently, UPC codes are often pre-printed on the corrugate box. This is because every item in a single SKU shares the same GTIN number. With 2D barcodes, manufacturers will have to account for a more data-rich bar code with variable data like lot codes, expiration dates, and serial numbers. This means barcodes must be printed on the distribution cartons in real-time.

For manufacturers who already have case coding and print-and-apply labelers on their packaging line, many will need to update their equipment to meet high-resolution print required by the newly adopted 2D barcodes. According to recent research provided by Packaging Machinery Manufacturers Institute (PMMI),  88% of snack food manufacturers to purchase new labeling and coding machinery by 2027. It will be essential that nearly all manufacturers, particularly those in consumer packaged goods (CPG), reevaluate their on-demand printing technology to comply with GS1 and customer requirements. 

Updating Labeling and Case Coding for GS1 2D Barcode Compliance

To accommodate 2D barcodes on secondary packaging, manufacturers will need to update or replace their case coding and printing equipment to ensure compatibility with the new high-resolution requirements of 2D barcodes. Unlike traditional 1D barcodes, 2D barcodes demand more sophisticated printing technology that can ensure sharp contrast, precise alignment, and high readability.

Comparing the Advantages of Direct Barcode Printing vs. Labeling on Cases

When it comes to case coding, manufacturers have two main options: printing barcodes directly on cases or applying labels with barcodes. Each approach offers distinct advantages, but direct printing is increasingly favored for modern packaging lines.

Direct Barcode Printing with Inkjet Printer:

1. Cost Savings: Printing barcodes directly on cases eliminates the need for label materials. On average, the cost per print is about 1/5 the cost of labeling.
2. Uninterrupted Production: Inkjet printers can print 10 times more cases than labeling before requiring ink replacement, meaning fewer interruptions in production
3. Speed and Efficiency: Direct printing can often be faster, integrating seamlessly into the production line without the added step of label application.
4. Sustainability: By removing the need for label materials and adhesives, direct printing reduces waste and improves sustainability.
5. Print Durability: Printed barcodes are less likely to peel off or be damaged, making them more reliable throughout the supply chain.
   
   

Labeling Cases with Print & Apply Labeler:

1. Print Contrast: Labels allow better print contrast for scanability on dark or patterned substrates.
2. Non-Porous Substrates: Labels are often used for coated boxes or shrink-wrapped bundles; however, UV cured and solvent based inks, like those used in the Integra PP Razr, can be used in some inkjet printers for non-porous surfaces.

While labeling may be the best choice in certain cases, inkjet printing generally offers a more cost-effective, faster, and flexible solution for case coding. With Sunrise 2027 pushing for variable data on packaging, direct printing will become a more practical and scalable solution for meeting new compliance requirements and ensuring efficient supply chain operations.

What Inkjet Technology is Best for Your Case Coding Needs?

The most immediate and significant change will be to ensure your case coding and printing technology can accommodate 2D barcodes. Thermal Inkjet (TIJ) and Piezo Inkjet (PIJ) technologies both are well suited to meet case coding requirements for Sunrise 2027; however, each offer unique benefits depending on the specific needs of an operation.

• Thermal Inkjet (TIJ) is best for companies looking for a low-cost, low-maintenance, high-resolution solution for porous surfaces with moderate production volumes.
• Piezo Inkjet (PIJ), on the other hand, is ideal for manufacturers with high-volume, industrial environments that require reliable printing on various substrates (porous and non-porous), more robust systems, and long-term operational efficiency.

Both technologies are valuable for different case coding applications, and the choice depends on your production needs, substrate types, and budget. Here's a comparison of both:

Thermal Inkjet Case Coding (TIJ)

• Cost: TIJ systems are generally more affordable upfront, making them a cost-effective solution for companies with lower budgets or simpler coding needs.
• Maintenance: TIJ printers are low-maintenance due to their use of disposable print heads, which means operators can quickly replace them without needing extensive cleaning or repairs.
• Print Quality: While both have high-resolution to support quality 2D codes, the Piezo Inkjet Printers typically max out around 300dpi. Thermal Inkjet can provide high resolution (up to 600 DPI), making it ideal for case coding applications where clarity of small alphanumeric codes, date codes, or barcodes is exceptionally critical.
• Speed & Volume: While Thermal Inkjet printers excel at high-resolution printing, traditional TIJ systems use a 50ml cartridge and are not well suited for high-volume operations, especially for large, continuous runs. Some advanced TIJ systems, like the CLARAjet, offer bulk ink options to help mitigate this issue, providing more ink per cartridge.
• Consumables: Because TIJ printers use disposable cartridges, there are ongoing consumable costs resulting in a higher cost-per-print compared to Piezo Inkjet. Again, bulk ink options can help reduce cost-per-print by allowing you to reuse ink cartridges.
• Print Height: Traditional TIJ printers use 1/2-inch tall print heads, limiting print height. While some systems can "stitch" multiple heads together to reach larger heights, they typically max out at 2-inches. New TIJ 4.0 printers feature a 7/8-inch tall print head and can be combined to print up to 3.5-inches, offering greater flexibility for larger print requirements.

Piezo Inkjet Case Coding (PIJ)

• Cost: PIJ systems, like the Foxjet NetSeries, have a higher upfront cost compared to TIJ, but provide much lower cost per print along with advanced capabilities and durability.
• Maintenance: Unlike Thermal Inkjet, Piezo Inkjet print heads are non-disposable and can be rebuilt, reducing the need for frequent replacements. This lowers Total Cost of Ownership over the life of the printer and makes PIJ more suitable case coding solution for high-volume packaging operation.
• Print Quality: PIJ systems offer high-quality printing, typically up to 300 DPI, which is more than sufficient for large barcodes, text, and graphics on secondary packaging. It excels in durability for printing on non-porous surfaces like shrink-wrapped or coated boxes, where TIJ might struggle.
• Speed & Volume: PIJ is designed for higher throughput, making it ideal for industries with heavy production demands.
• Print Height: Designed specifically for case coding, Piezo Inkjet systems provide larger print height, up to and above 4-inches in a single print head, allowing for larger print area.

Featured Case Coding Solutions

CLARAjet Thermal Inkjet Case Coder

The CLARAjet is a premier inkjet solution for high-quality case coding. It leverages Thermal Inkjet 4.0 technology from Hewlett Packard and a revolutionary pressurized bulk-ink system, offering the best advantages of both Thermal Inkjet (TIJ) and Piezo Inkjet (PIJ) technologies. This combination delivers the low upfront costs and eliminated maintenance of TIJ with the low cost per print and high-volume performance of PIJ.

Each TIJ 4.0 printhead can print at 7/8 inch, and multiple heads can be used to produce seamless, high-resolution prints up to 3.5-inches tall, making it ideal for larger coding needs. Its compact, All-in-One design facilitates easy integration into nearly any packaging line, providing high-resolution printing for alphanumeric codes, lot numbers, barcodes, and graphics. The CLARAjet is a cost-effective, reliable solution, well-suited for adapting to evolving coding requirements, including those of the upcoming Sunrise 2027 regulations.

Foxjet Piezo Inkjet Printer

The Foxjet NetSeries uses proven piezo inkjet (PIJ) technology, providing a scalable and efficient solution for high-volume packaging operations. It is capable of printing high-resolution (300 DPI) alphanumeric codes, barcodes, and graphics directly onto cases, which eliminates the need for labels. The NetSeries printer can also handle GS1 barcode requirements, ensuring compliance for secondary packaging.

This system is highly adaptable, offering 2-inch and 4-inch printheads and advanced features like a patented quick-connect printhead, instant self-cleaning cycles, and real-time ink monitoring. The NetSeries' modular design allows for easy integration into packaging lines, with minimal downtime and reduced maintenance costs. Its flexibility in printing variable data such as lot numbers and expiration dates makes it future-proof as coding regulations evolve with initiatives like Sunrise 2027.

With the Foxjet NetSeries, inkjet printing becomes a durable, efficient, and long-lasting solution for meeting today's and tomorrow's packaging requirements.

Conclusion: Act Now for a Seamless Transition

Sunrise 2027 is an important milestone for global supply chains, and the shift to 2D barcodes will have wide-reaching effects throughout manufacturing, packaging, and distribution operations. Manufacturers that invest in high-resolution case coders, upgrade their printing systems, and optimize their processes today will be well-positioned to comply with GS1 standards, meet evolving customer requirements, and thrive in a more efficient, data-driven supply chain ecosystem. For additional assistance, contact Pak-Tec for additional guidance on determining what case coding is best for your specific needs.

*Feature image from GS1 US