Variable Barcodes and Batch Coding Printed Inline for a High-Volume Cosmetics Range

The Challenge

What Was the Problem?

Aravind Laboratories ships the Eyetex range in huge volumes across many SKUs and batches. Each pack needs an accurate variable barcode plus alphanumeric batch, MFG, EXP and price characters. Offline and manual coding was causing scan failures, smudged codes and occasional batch mismatches that slowed dispatch.

Our Solution

What We Did

We used variable data printing to print the variable barcode and the alphanumeric batch and date characters inline on the label in a single press pass, merged directly from the client's data file. An inline verification step checked every barcode for first-scan readability, so coding was no longer a separate, error-prone step.

The Results

What Changed

First-scan accuracy rose to near-perfect, batch-coding mismatches were eliminated, and changeovers between SKUs and batches became faster because the data was driven from a file rather than reset by hand. The line ran cleaner and dispatch sped up.

Background

A fast-moving cosmetics brand lives on volume and accuracy. When coding is a separate manual step, every SKU and batch change is a chance for error. The fix was to make the variable data part of the print itself.

What We Changed

• Technology: variable data printing for inline barcode plus alphanumeric characters
• Accuracy: inline barcode verification for first-scan readability
• Data: batch, MFG, EXP and price merged from the client's file
• Efficiency: faster, error-free SKU and batch changeovers

Why It Worked

Manual coding fails because it is a second, separate step. Printing the variable barcode and characters inline, verified as they print, removes the step where errors used to creep in.