The Cost of Illegible Product Identification: Why Print Quality Matters More Than You Think

The Cost of Illegible Product Identification: Why Print Quality Matters More Than You Think

Chris DavisIndustry News

It’s just a barcode – until it’s not.

Across warehouses, production lines, and store shelves, a single illegible or unreadable barcode can derail operations, delay shipments, and cost companies thousands. While barcode misprints might seem like a minor detail, the downstream impact they create can be anything but small.

In a 2022 GS1 US survey, over 60% of retailers reported receiving shipments with barcode readability issues.

So what’s really at stake when barcodes go bad?

The Hidden Costs of Poor Barcode Quality

Operational Disruptions

Unreadable barcodes slow everything down. Automated systems halt, staff are forced to relabel or manually input data, and entire shipments can be delayed.

  • Production slowdowns
  • Manual rework
  • Shipping errors and reroutes

Inaccurate transactional data can cost up to 25% more in labor

Inventory and Supply Chain Errors

Barcode misreads create a ripple effect – leading to inaccurate inventory counts, overstocking, stockouts, and delivery errors.

  • Mispacks and misplaced products
  • Lost inventory visibility
  • Increased labor for resolution

Inventory inaccuracy accounts for 8.7% of lost sales

Retail & Regulatory Consequences

Big-box retailers and regulated industries don’t tolerate poor labeling.

  • Chargebacks ranging from $50 to $500+ per pallet
  • Rejected shipments
  • Regulatory compliance failures (especially in food, pharma, and healthcare)

A single mislabeled shipment can cost thousands and damage vendor relationships.

Brand Reputation & Customer Experience

Even if your barcode failure doesn’t cause a compliance issue, it can hurt your brand.

  • Poor perceived quality
  • Customer frustration
  • Lost sales at checkout if products can’t be scanned

86% of consumers are unlikely to buy products from a brand after an experience with inaccurate product information

The Solution: High-Quality, Reliable Coding and Marking Systems

Preventing these issues starts with your coding and marking technology. Investing in advanced technology ensures sharp, legible product identification across the product lifecycle – from the production floor to the end customer.

REA JET systems are flexible, reliable, and built to deliver:

  • Consistent barcode readability even on curved, textured, or dark surfaces
  • High-speed print performance that keeps up with modern production lines
  • Long-lasting marks that resist abrasion, smudging, and fading

While you may not know the cost of product loss right away – your supply chain will. Print quality is not just a technical detail; it’s a strategic business safeguard.

Let REA JET help you build reliability into every mark.