I was the receiver. 3 AM shift. 40 cartons per minute. If a barcode didn't scan in under 100 milliseconds, the whole line stopped.
After five years, I can tell you more about why barcodes fail than most people learn in a career.
The Three Rules Nobody Follows
White space is not optional. Every barcode standard specifies a quiet zone on both sides. UPC requires 9x the narrowest bar
width. ITF-14 requires 10x. If you print edge-to-edge, your scanner sees noise instead of a barcode. I rejected entire pallets for
this.Brown cardboard is not white. Laser scanners read contrast—black bars against a white background. Corrugated cardboard is beige.
Print directly on it, and the "white" spaces aren't white. Every vendor who skipped the white label step learned this at the
receiving dock.Test-scan before printing 1,000 labels. One bad print run at 3 AM costs hours. I print 10 labels and scan all 10. If one fails, I
recalibrate. The scanner is your QA tool.
Why I Built a Free Tool
After Amazon, I started consulting for small warehouses. Every owner asked the same question: "How do I track inventory without
Spending $10K on a WMS? "The first thing they all needed—before any software—was clean, scannable barcodes.
I built https://genbarcode.org because the existing free generators were loaded with ads, watermarks, and required signup. Mine
runs entirely in your browser. Type a number, get a barcode. No upload. No account. Supports EAN-13, UPC-A, Code 128, ITF-14, and
Code 39.
What Format to Use
┌───────────────────┬────────────────┬────────────────────────────┐
│ Use case │ Format │ Why │
├───────────────────┼────────────────┼────────────────────────────┤
│ Retail product │ UPC-A / EAN-13 │ Global POS standard │
├───────────────────┼────────────────┼────────────────────────────┤
│ Shipping carton │ ITF-14 │ Designed for corrugated │
├───────────────────┼────────────────┼────────────────────────────┤
│ Warehouse bin │ Code 128 │ Alphanumeric, dense, fast │
├───────────────────┼────────────────┼────────────────────────────┤
│ Internal tracking │ Code 39 │ Legacy support, easy print │
└───────────────────┴────────────────┴────────────────────────────┘
If you're printing your own labels for the first time, use Code 128 at 300 DPI on white labels. Test on the surface you're actually
labeling—not office paper. And leave the quiet zone. Your receiver will thank you at 3 AM.
Marcus Rivera is a former Amazon warehouse operations manager. He builds free barcode tools at https://genbarcode.org
