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Introduction: The Common Barcode Scanning Problem
Have you ever faced this issue in your warehouse or during logistics operations?
You scan a product label—only to realize it has multiple barcodes placed closely together. Your worker accidentally scans the wrong one, leading to:
- Wrong item picking
- Shipment delays
- Incorrect inventory updates
- Even costly returns
This is a common but preventable problem in busy warehouse environments, especially when labels contain multiple barcodes of similar symbology (e.g., Code39, Code128).
The Solution: Set a Barcode Length Filter
A simple yet powerful solution is to configure your barcode scanner to recognize only barcodes of a specific length.
This is known as a Barcode Length Filter or Barcode Data Length Filtering. Here’s how it works:
- If all barcodes on the label are using the same symbology (e.g., Code39), but only the correct one has a fixed length (say, 8 characters), you can tell the scanner to accept only Code39 barcodes of length 8.
- The scanner will ignore all others—even if they’re nearby.
- This prevents mis-scanning and boosts picking/shipping accuracy.
✅ Example: Label includes these barcodes:
- Code39:
12345678(Correct) - Code39:
ABC(Ignore) - Code39:
87654321ABC(Ignore)
By setting the filter for Code39 with a length of 8, only 12345678 is scanned.
Step-by-Step: How to Set a Barcode Length Filter
1. Identify the Barcode Symbology on Your Label
- Look at your product labels. Are they Code39, Code128, or another type?
- Most barcode scanners support length filtering per symbology.
2. Find the Correct Barcode Length
- Measure the length (number of characters) of the barcode you want your scanner to read.
- Make sure it’s a fixed length used consistently across your operations.
3. Access the Scanner Configuration Tool
- Most scanners can be configured via:
- A printed programming guide (with barcodes to scan)
- A USB connection and configuration software (e.g., Zebra 123Scan, Honeywell EZConfig)
- An Android configuration app (if using mobile computers)
4. Set the Minimum and Maximum Lengths
- For example, if your valid barcodes are always 8 characters, set:
- Minimum Length = 8
- Maximum Length = 8
5. Save the Settings and Test
- Try scanning a label with multiple barcodes.
- The scanner should now ignore short/long codes and only capture the one with the specified length.
Why This Matters
🔒 Fewer errors – Avoid scanning the wrong barcode during order picking. 📦 Faster operations – Reduce time spent rescanning or verifying. 💰 Lower cost – Prevent incorrect shipments and avoid return costs. 📊 Better data – Improve scan accuracy for WMS or ERP systems.
🎥 Watch It in Action
Check out our quick tutorial video showing how this feature works in a real warehouse. See how workers use length filtering to speed up and clean up their scanning process.
Need Help Setting This Up?
At EFFON, we provide barcode scanners, wearable scanners, and Android mobile computers that fully support barcode length filtering.
Our technical team can help you configure this feature based on your barcode format and warehouse system.
📩 Contact us at info@effon.com or visit 🌐 www.effon.com
