Sunrise 2027: How to Print GS1 2D Codes on the Production Line with Pleyon

What is changing with GS1 2D codes, and why does print quality determine whether a DataMatrix or QR Code can be read at checkout? Discover Pleyon by Fam Printing.

Sunrise 2027: Printing GS1 2D Codes with Pleyon

By the end of 2027, retailers aim to enable point-of-sale systems to read GS1 2D codes alongside traditional EAN and UPC barcodes. For manufacturers and packaging companies, the challenge is not simply choosing a code format, but printing it accurately at production-line speed and on different types of packaging. Let's explore what is changing and how to prepare.

What Is GS1 Sunrise 2027?

Sunrise 2027 is the goal shared by GS1 and the retail industry to enable point-of-sale systems to read the GTIN contained in both linear barcodes and 2D codes by the end of 2027. According to the GS1 guideline, the transition is voluntary and industry-driven. It is not a legal requirement, although retailers may request that their suppliers adopt it.

EAN and UPC barcodes contain only the GTIN, which identifies the product. 2D codes can contain much more information, including batch numbers, expiry dates, serial numbers and, through GS1 Digital Link, a link to online information for consumers.

For retail applications, GS1 identifies three options: GS1 DataMatrix, QR Code with GS1 Digital Link, and Data Matrix with GS1 Digital Link.

What Changes for Manufacturers?

Linear barcodes are not disappearing. During the transition, packaging will carry both an EAN/UPC barcode and a 2D code. This practice is known as dual marking.

• The linear barcode remains necessary during the transition. Until at least 90% of point-of-sale systems can read GS1 2D codes, products carrying a 2D code must also display a linear barcode.
• Positioning. According to GS1 guidance, the 2D code should be positioned within 50 mm of the centre of the linear barcode to avoid slowing down the checkout process.
• Data. The GTIN is the only data required for Sunrise 2027. Batch numbers, expiry dates and serial numbers are variable data that can be printed on the production line during packaging, whereas the GTIN is often already preprinted on the packaging.
• No fixed deadline for removing linear barcodes. As 2D code scanning becomes more widespread, manufacturers can choose whether to use only a 2D code, both formats, or only the linear barcode.

Why Print Quality Is Critical

A 2D code containing the correct data will not scan at checkout if it is poorly printed. The GS1 guideline requires codes to comply with the GS1 General Specifications and refers to ISO/IEC 15415 for verification when graphic modifications or print-quality concerns arise. The following parameters are particularly important:

• Module size (X-dimension). For 2D codes, the permitted values are 1.5 times those of equivalent linear barcodes. If the modules are too small, the code becomes more difficult to read.
• Quiet zone. This is the blank margin surrounding the code: one module wide for DataMatrix and four modules wide for QR Code.
• Contrast and colour. Black printing on a white background is generally the most reliable combination. Since scanners use red light, red, orange and yellow codes can be difficult to decode.
• Pattern integrity. Distorted modules, decorative shapes or logos inside the code can consume error-correction capacity and reduce readability.

On the production line, other factors also come into play, including conveyor speed, surface type (cardboard is porous and absorbs ink) and the distance between the printhead and the package.

What to Look for in a 2D Code Printer

Before choosing a system, check these six requirements and request a print test on your own packaging.

• High resolution: small modules and sharp edges, including for compact codes.
• Sufficient print height: the ability to print a 2D code, text and variable data in a single pass.
• Adequate printhead-to-surface distance: tolerance for variations in package positioning.
• Suitable printing speed: consistent quality at the actual production-line speed.
• High-contrast ink: reliable readability on cardboard and other porous substrates.
• Variable data and integration: batch numbers, expiry dates and serial numbers generated and printed directly on the production line.

After printing, quality should be measured using a barcode verifier, with the results recorded. A code that can simply be read by a handheld scanner is not necessarily sufficient.

How Pleyon Meets These Requirements

Pleyon, part of the FAMJET® range, is an HP 2.5 TIJ solution designed for high-volume printing. It uses ½-inch HP45 cartridges supplied by a 400 ml bulk ink system. The following specifications are particularly relevant to 2D code printing:

• Technology: HP 2.5 Thermal Inkjet (TIJ), using HP45 cartridges.
• Maximum resolution: 2,400 dpi.
• Printing speed: 130 m/min at 150 dpi.
• Maximum print height: 25 mm, with up to two printheads.
• Consumables: 400 ml bulk ink system, available with water-based or solvent-based ink.
• Communication and interfaces: Ethernet, Wi-Fi, industrial I/O, NiceLabel printing drivers, photocell and encoder.
• Display and memory: 9-inch touchscreen, with 16 GB or 32 GB memory options.

For GS1 2D codes, resolution and print height are particularly important. In the example provided in the GS1 guideline, a GS1 DataMatrix with a module size of 0.495 mm measures approximately 19 mm in width, meaning it fits within a 25 mm print area. The stated printing speed applies at 150 dpi. The combination of resolution and production-line speed must be verified through a print test. FAM also indicates a printing cost reduction of more than 60% with the 400 ml bulk system.

The actual verification grade depends on the substrate, encoded data and printing conditions. This is why testing on your own packaging is recommended.

Checklist: How to Prepare for Sunrise 2027

1. Select the products to start with and choose the 2D format (GS1 DataMatrix or QR Code with GS1 Digital Link).
2. Ensure that each product has a GS1 GTIN and that the required variable data (batch number, expiry date and serial number) can be generated.
3. Define the position of the 2D code relative to the linear barcode, keeping it within 50 mm of the barcode's centre, and ensure the required quiet zones are maintained.
4. Choose the printing technology according to the substrate and production-line speed.
5. Test printing on actual packaging and measure the verification grade with a barcode verifier.
6. Agree on specifications with retail customers and incorporate quality checks into the production line.

Test Pleyon on Your Packaging

Sunrise 2027 does not require manufacturers to change their codes overnight. The goal is to reach the end of 2027 with 2D codes that can be read reliably. The simplest way to understand your current position is to conduct a print test on your own cartons, using your data and your actual production-line speed.

To arrange a print test or request a Pleyon demonstration, email info@fam-printing.com, call +39 0362 302877, or visit www.fam-printing.com.

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