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100Module 10 of 15

Barcodes 101: GTIN/UPC/EAN

Placement, quiet zones, min/max sizes, avoiding distortion, and verification basics.

7 minutes
barcodes
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Lesson Video
Barcodes 101: GTIN/UPC/EAN
Module Content

1) Executive Summary

Top insights (5–7)
  1. EAN-13/UPC-A magnification for POS is 80–200% (target X-dimension 0.33 mm). Under strictly controlled on-demand printing, some GS1 MOs allow ~75% minimum—confirm locally. [1][2][4]
  2. Quiet zones are non-negotiable. At 100%: UPC-A requires ≥ 9X left/right; EAN-13 requires ≥ 11X left and ≥ 7X right. Scale with magnification. [1][2][4]
  3. Bar height matters—do not truncate. At 100%, EAN-13/UPC-A bar heights are ~22.85 mm (excl. guard extensions); practical minima under ~16 mm risk failures. [1][4]
  4. Placement for POS: lower-right back panel, 8–102 mm from edges; avoid seams, folds, corners; keep flat. [3]
  5. Curved packs: use ladder orientation (bars vertical). If horizontal, symbol total width (incl. quiet zones) must be ≤ 1/6 circumference. [3][4]
  6. Verification: Design to pass ≥ 1.5/06/660 (Grade C) per ISO/IEC 15416 for POS EAN/UPC. [4][7]
  7. Roadmap: Retail is transitioning to 2D@POS by ~2027. Linear EAN/UPC will coexist; plan dual-marking and maintain linear compliance. [5][6]
Recommended near-term actions (3–5)
  • Lock EAN-13/UPC-A at 100–120% where space allows; avoid minimums. Preflight quiet zones and bar height first. [1][2]
  • For curved packs, use ladder orientation; confirm the 1/6 circumference rule. [3][4]
  • Mandate verification reports (ISO/IEC 15416) at first article + spot checks; require ≥ 1.5/06/660 for POS. [4][7]
Risks & watch-outs (12–24 months)
  • Rising 2D@POS pilots; reserve space and maintain linear compliance. [5][6]
  • More retailer QA failures for quiet zones and truncation, especially on shrink films and metallised boards. [4]

2) Definitions & Concepts

  • GTIN. Global Trade Item Number (8/12/13/14 digits); EAN-13 encodes GTIN-13; UPC-A encodes GTIN-12. [8]
  • X-dimension. Width of the narrowest bar/space; controls size. [1]
  • Quiet zone. Clear area left/right of symbol, measured in modules (X). [1][2]
  • Magnification. Size % relative to 100% nominal (80–200% for POS). [1][2]
  • Truncation. Reducing bar height—don’t. [4]
  • Verification grade. ISO/IEC 15416 grade A–F; GS1 minimum C (1.5). [4][7]
  • 2D@POS. GS1 DataMatrix/QR with GS1 syntax coexisting with linear during transition. [5][6]
Concept map (bullet diagram)
  • GTIN → EAN-13 / UPC-A → sized by X & magnification → sets bar height & quiet zones → accurate placement (edge rule; curvature) → print tuning (BWR, color, substrate) → verification (ISO/IEC 15416) → scan success. [1][2][3][4]

3) Standards, Regulations, and Governance

Authoritative stack
  • GS1 General Specifications & MO guidance (AU/UK/US factsheets; GS1 US placement). [1][2][3][4]
  • ISO/IEC 15416 (print quality method), ISO/IEC 15426-1 (verifier conformance). [7]
Per-region notes (US / EU / UK)
  • Code usage: US: UPC-A (GTIN-12); EU/UK: EAN-13 (GTIN-13). Modern POS reads both. [9]
  • Placement rules: GS1 US edge rule (8–102 mm) widely adopted; UK stresses avoiding seams/folds and curvature issues. [3][4]
  • Verification: Minimum grade ≥ 1.5 with GS1 apertures/wavelength (POS EAN/UPC typically 06/660). [4]
  • 2D@POS: Global Sunrise/Ambition 2027—dual-marking; linear remains valid. [5][6]
What differs by region (summary)
TopicUSEUUK
Common retail POS codeUPC-A & EAN-13EAN-13 & UPC-AEAN-13 & UPC-A
Preferred placementLower-right back; 8–102 mm from edgesSimilar; MO guidanceSimilar; strong seams/curvature guidance
Verification minimum≥ 1.5/xx/660 (C)SameSame (explicit)

Known upcoming change: scaling 2D@POS pilots; more retailers accept GS1 2D alongside linear through 2027+. [5]

4) Evidence Base & Benchmarks

Canonical dimension tables (retail POS)
EAN-13 (GTIN-13)
  • 100%: X = 0.33 mm; width excl. quiet zones = 31.35 mm; bar height = 22.85 mm; quiet zones: L = 3.63 mm (11X), R = 2.31 mm (7X). [1]
  • Range: POS 80–200%; General Distribution 150–200%. [1]
UPC-A (GTIN-12)
  • 100%: X = 0.33 mm; width excl. quiet zones = 31.35 mm; bar height = 22.85 mm; quiet zones: L = R = 2.97 mm (9X). [2]
  • Range: POS 80–200% (on-demand minima may reach ~75% where permitted); General Distribution 150–200%. [2]
Placement benchmarks
  • Edge rule: Keep symbol 8–102 mm from any package edge; lower-right back panel preferred. [3]
  • Curvature: Ladder orientation on small radii; if horizontal, total width (incl. quiet zones) ≤ 1/6 circumference. [3][4]
Verification benchmarks
  • Pass criteria: ≥ 1.5/xx/660 (Grade C) using GS1 aperture/wavelength (POS typically 06/660). [4][7]
  • Method: ISO/IEC 15416 (10 scans across 80% inspection band; lowest parameter per scan → average → overall). [7]

Where data conflict: MO factsheets can differ for on-demand minima; defer to current local MO document. Evidence gap: compiled global table of MO-specific minima. [1][2][4]

5) Design & Production Implications

Rules of thumb (with sources)
  • Start from the barcode. Reserve area for 100–120% symbols + quiet zones early. [1][2]
  • Never truncate. Truncation is a top failure cause. [4]
  • Curved surfaces: choose ladder; validate 1/6 circumference; avoid edges/seams. [3][4]
  • Color & substrate: Black bars on white; avoid red/orange bars, metallics, and transparent show-through; use white underlay where needed. [4]
  • Generate proportionally. Don’t stretch; generate vector art at target magnification; apply BWR per process and verify. [4]
ChoiceCostRiskScan reliabilityNotes
Paperboard + litho●●Low BWR controlHighStable; beware varnish glare. [4]
Film + flexo●Ink spread/voidsMediumShrink & curl can distort bars. [4]
Clear/metallic●●Contrast lossLow→MediumUse opaque white box. [4]
Manufacturability flags
  • BWR tolerance varies by press/substrate; proof with verification.
  • Keep symbols ≥ 8 mm away from seams/folds; maintain flatness at POS scan path. [3][4]
Supplier expectations

Provide EPS/SVG barcode art at target magnification with BWR applied; submit first-article verification report showing ≥ 1.5/06/660 (or better) for POS. [4][7]

6) Sustainability & Compliance Considerations

  • Pre-verification reduces waste from reprints after QA fails. [4]
  • During dual-mark era, if adding a 2D code, keep linear quiet zones clear and avoid clutter. [5]
  • Keep environmental icons/OPRL/How2Recycle marks outside quiet zones and away from bars. [3][4]

7) Workflow & Tooling (ready for PDA tools)

Checklists
Pre-press EAN/UPC (POS)
  • Correct GTIN (checksum) and symbology (EAN-13 vs UPC-A). [4]
  • Magnification 80–200% (target 100–120%). [1][2]
  • Quiet zones: EAN-13 L ≥ 11X, R ≥ 7X; UPC-A L=R ≥ 9X. [1][2]
  • Bar height not truncated; guard bars extended. [1][2]
  • Placement: lower-right back; 8–102 mm from edges; flat plane. [3]
  • Curved packs: ladder orientation; 1/6 circumference rule if horizontal. [3][4]
  • Colors/substrate adequate; white background where needed. [4]
  • Verification plan: ≥ 1.5/06/660 target; first-article + periodic. [4][7]
Decision trees
  • EAN-13 vs UPC-A: US-only legacy GTIN-12 → UPC-A; global/EU/UK → EAN-13; mixed retail → either (prefer MO-native). [9]
  • Curved surface orientation: Small radius → ladder; wide cylinder → ladder preferred; if horizontal, ensure ≤ circumference/6. [3][4]
Calculator blueprints
  1. UPC-A 100% seeds: width_excl_QZ = 31.35 mm; bar_height = 22.85 mm; quiet zone each side = 2.97 mm (9X). For magnification M, multiply by M/100. [2]
  2. EAN-13 100% seeds: width_excl_QZ = 31.35 mm; bar_height = 22.85 mm; quiet zones L = 3.63 mm (11X), R = 2.31 mm (7X). Scale by M/100. [1]
  3. Curvature check: If total width > circumference/6 → use ladder or reduce magnification (within POS limits). [4]
  4. GTIN checksum: modulo-10 per GS1 method. [4]
Template specs (RFQ fields)
  • GTIN(s); symbology; magnification %; X-dimension mm; bar height mm; quiet zone mm; placement panel; edge offsets; orientation (ladder/picket); substrate; ink; BWR; verifier target grade; aperture/wavelength. [1][2][3][4][7]

8) Category-Specific Guidance

Beauty (small cylindrical, films). Design for ladder; reserve height; use opaque white behind bars on tinted/metallic containers; watch shrink distortion on sleeves. [3][4]
Food (pouches, cartons). Keep off seal areas/zipper seams; apply edge rule; matte varnish reduces glare. [3]
Beverage (cans/bottles). Curvature dominates: ladder orientation; if horizontal, enforce ≤ circumference/6 and maximize magnification. [3][4]

9) Case Studies (Problem → Approach → Result)

CS-1: Shrink-sleeved beverage can failing POS (truncation)
Problem: 80% UPC-A placed horizontally on sleeve; bars truncated; fails in store.
Approach: Switch to ladder; increase to 110%; add opaque white panel; verify to ≥ 1.5/06/660. [3][4]
Result: Pass Grade B (~2.5); zero cashier rescans in pilot.
CS-2: Lip balm stick (tiny curved label)
Problem: EAN-13 at 80% wrapped horizontally; quiet zones breached by dieline.
Approach: Convert to EAN-8 (if eligible), or keep EAN-13 in ladder at 90%; respect 1/6 circumference; re-layout HRI. [4]
Result: Pass Grade C; improved first-pass read.
Evidence gap: peer-reviewed data on read-rate deltas by orientation on sub-30 mm diameters.
CS-3: Paperboard carton (gloss glare)
Problem: Variable fail due to specular reflections.
Approach: Move symbol to matte area; increase size to 120%; confirm 8–102 mm edge rule; verify. [3]
Result: Stable Grade B; improved cashier speed.

10) Common Pitfalls & Red Flags

  1. Quiet zones invaded by crops/graphics. [1][2][4]
  2. Truncation to “make it fit”. [4]
  3. Horizontal on tight curves without 1/6 check. [4]
  4. Colors: red/orange bars; metallic or transparent backgrounds. [4]
  5. Non-proportional scaling or bitmap resampling. [4]
  6. Edge rule violations; placed on corners/seams. [3]
  7. No verification at first article; relying on ad-hoc devices. [4][7]

References

Core sources: GS1 AU EAN-13 & UPC-A factsheets; GS1 US barcode placement guideline; GS1 UK “Barcoding – getting it right”; ISO/IEC 15416/15426 explainers; GS1 2D@POS implementation guides and national MO materials. See numbered references [1]–[9].

Sidebars

  • Designer tip — Make space early. Place a 45 mm (H) × 42–50 mm (W excl. quiet zones) keep-clear box for 100–120% symbols. [1][2]
  • Compliance watch — Dual-mark era. If adding a 2D code, keep linear quiet zones clear and avoid clutter. [5]
  • Manufacturing note — Verify the actual pack. Verify on representative substrates and finishes (matte/gloss; product inside for show-through). [4]

Visual prompts (for downstream slides)

  • Diagram: EAN-13/UPC-A anatomy with dimensions (X, guard bars, quiet zones). [1][2]
  • Decision tree: Orientation selection (flat vs curved; ladder vs picket). [3][4]
  • Calculator mock: Magnification → width, bar height, quiet zones for EAN-13/UPC-A. [1][2]
  • Checklist slide: Pre-press/pressroom verification steps (≥ 1.5/06/660). [4][7]
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