The Best Way to Design Barcode Labels: Best Practices from Label Experts

The Best Way to Design Barcode Labels: Best Practices from Label Experts

BY: BLAKE JANZ / DATE: 26/06/2026 / TOPICS: LABEL DESIGN, BARCODE BASICS

National Barcode Day is a reminder of how much businesses rely on barcode labels every day. From manufacturing and retail to logistics and healthcare, barcodes power critical workflows behind the scenes.

Creating a barcode may seem simple, but creating a barcode label that scans reliably throughout the supply chain requires much more than placing lines on a label. Barcode type, print quality and setup, accurate data, materials, and environmental conditions all play a role in long-term performance. 

If any part of that process is overlooked, your team might face consequences that can be significant:

• Shipping errors
• Inventory inaccuracies
• Production delays
• Compliance issues
• Chargebacks or fines

To better understand what separates high-performing barcode labels from problematic ones, we asked a few TEKLYNX labeling experts to share their advice on creating accurate, reliable barcode labels. 

TRY BARCODE LABELING SOFTWARE FOR FREE 

Design for the scanner, not the screen

Question 1: What barcode design best practice is often overlooked but makes the biggest difference?

Dominic Bieniewski, TEKLYNX Sales Engineer: Design for consistency across devices and conditions. That means sizing barcodes correctly from the start and ensuring they will print and scan reliably across different printers and environments.

A barcode that looks perfect in a design file may fail once it's printed or applied to packaging. Successful barcode design starts with understanding how the label will be used in the real world.

Some of the most important design considerations include:

Choosing the right barcode symbology

One of the first decisions in barcode label design is choosing the right barcode symbology. Each barcode type has a different purpose, so the best choice depends on how the label will be used.

For example, a retail product may need a UPC or EAN barcode. A logistics label may require GS1-128. Smaller items or regulated products may use a 2D barcode, such as GS1 DataMatrix. QR Codes and GS1 Digital Link barcodes are also becoming more common as businesses look for ways to connect physical products to more detailed digital information.

Choosing the wrong barcode type can create problems later. The barcode may not hold the right amount of data, meet trading partner requirements, or scan correctly in the environment where it is used.

Before designing a barcode label, consider:

• What information needs to be encoded
• Where the barcode will be scanned
• What type of scanners will be used
• Whether the label needs to meet GS1, industry, or customer requirements
• How much space is available on the label
• Whether the barcode needs to support variable data such as lot numbers, expiration dates, serial numbers, or production dates. 

TEKLYNX barcode label design software helps simplify this process with built-in barcode wizards, including GS1 barcode creation tools in CODESOFT and LABELVIEW. These tools guide users through barcode creation, so they can select the correct barcode type and add the required data with less manual formatting.

For GS1 barcode labels, this may include Application Identifiers for information such as GTIN, lot number, serial number, production date, best-by date, packaging date, or expiration date.

As barcode standards continue to evolve, choosing the right symbology is one of the most important steps in creating labels that support your current needs and future labeling requirements. 

Designing for barcode readability, size, and reliable scanning

Barcode size matters just as much as the barcode type, and barcode readability should be considered throughout the design process, not just at the end.

When designing barcode labels, consider these readability factors:

• Quiet zone: Leave clear space around the barcode so scanners can identify where the barcode begins and ends. Scanners use quiet zones to determine where the barcode begins and ends. Text, graphics, or logos placed too close to the barcode can interfere with scanning performance.
• Barcode size: Make sure the barcode is large enough for the scanner and scanning distance.
• Contrast: Use strong contrast between the barcode and the background. Dark barcodes printed on light backgrounds provide the most reliable scan performance. Reflective materials and low-contrast color combinations can make barcodes difficult to read even if they appear clear on screen.
• Label surface: Consider whether the barcode will be applied to a flat, curved, flexible, or textured surface.
• Orientation: Make sure the barcode orientation works with the printer, scanner, and product packaging.
• Human-readable text: Include readable text when users need to confirm the encoded information manually.

Color can also be part of a barcode label design, but it should be used carefully. Color can support branding, product identification, warnings, or visual organization. The barcode itself should remain clear and easy to scan. Avoid placing graphics, colors, or other design elements too close to the barcode if they interfere with readability.

TEKLYNX barcode label design software allows users to add high-resolution graphics and use exact RGB or CMYK color codes with compatible color printers. These tools can help create more polished labels, but the barcode should always remain the most functional part of the design.

Build labels for real-world conditions

Question 2: What’s a barcode issue people often blame on the barcode when the real problem is something else?

Scott Fabian, TEKLYNX Product Integration Developer: A great barcode label is more than a barcode. It's a combination of the barcode, the material, the placement, the printer, and the environment all working together.

Many barcode issues are often caused by factors outside the barcode itself, like:

• Incorrect printer settings
• Poor print quality
• Incompatible label materials
• Environmental exposure
• Improper barcode placement 

Labels may be exposed to heat, cold, moisture, chemicals, sunlight, or frequent handling. What appears to be a barcode failure is often a durability or print quality issue.

Barcode placement also matters. Labels applied to curved surfaces, flexible packaging, or uneven containers can distort the barcode and reduce readability.

The best barcode labels are designed for the entire lifecycle of the product, like shipping and handling, not just the moment the label leaves the printer.

Start with the right printer setup

One often overlooked part of barcode quality is printer configuration. A label design is only as reliable as the printer setup behind it. If the printer, driver, label stock, and settings are not aligned, the final label may not print the way it appears on screen.

This is especially important for barcode labels because poor print quality can affect scanability. A barcode that is too light, too dark, distorted, or printed at the wrong size can cause problems in production.

Before printing barcode labels, confirm:

• The correct printer is selected
• The correct printer driver is installed
• Label size and page setup match the physical label stock
• Print speed and darkness settings are appropriate
• The label material and ribbon are compatible
• The printer can support the barcode size and resolution needed

TEKLYNX has developed over 4,000 native label printer drivers to help optimize print quality and printer performance. Native printer drivers help labeling software communicate more effectively with label printers and can support printer-resident features, such as fonts and barcodes.

Printer-resident fonts are installed on the printer itself rather than only on a computer. When used correctly, they can reduce the amount of data sent to the printer, which can help speed up label printing.

Printer setup may sound like a technical detail, but it plays an important role in barcode label design. A well-designed label still needs to print clearly and consistently to work as intended. 

Accurate data leads to accurate labels

Question 3: What is one labeling best practice every company should implement? 

Maddie Henry, TEKLYNX Support Engineer: Use a single, trusted source of data and eliminate manual entry when possible.

Manual data entry introduces unnecessary risk through:

• Typos
• Inconsistent formatting
• Outdated information 

A better approach is to create reusable label templates that pull variable data directly from ERP, WMS, MES, or other business systems.

Variable data may include: 

• Product name
• Item number
• GTIN
• Lot number
• Serial number
• Expiration date
• Production date
• Customer-specific information
• Shipping or inventory data

This approach helps reduce the number of label files your team needs to maintain. It also makes updates easier because the design and the data are not being managed in dozens or hundreds of separate files.

For example, a company with many product variations may only need a few smart label templates. When it is time to print, the correct product data is pulled into the label automatically.

TEKLYNX barcode labeling software makes it easy to connect label templates to local or cloud-enabled data sources. Database connection tools help users bring variable data into label designs, so teams can create a more consistent and scalable labeling process.

SEE HOW TEKLYNX SIMPLIFIES BARCODE LABEL DESIGN

Test barcode labels before production

Question 4: If you could check only one thing before a barcode label goes live, what would it be? 

Robert Lenski, TEKLYNX Engineering Team Lead: Verify that the barcode scans correctly using the actual scanners and conditions it will encounter in production.

Testing is often the fastest and least expensive way to improve barcode performance. 

Before deployment, organizations should confirm:

• The barcode scans successfully
• The correct data is encoded and returned after scanning
• Labels perform correctly after application, especially those exposed to moisture, heat, chemicals, etc.
• The barcode remains readable throughout shipping, storage, and use

A small pilot run or test print can identify problems before they become expensive operational issues.

Some industries may also require barcode verification. Barcode verification grades barcode quality against defined standards and helps confirm that barcodes can be scanned reliably throughout the supply chain.

Testing barcode labels before production helps reduce failed scans, rejected shipments, reprints, and other labeling issues that can slow down operations.

Why better barcode label design matters

Better barcode label design can improve more than the look of a label. It can help teams print more efficiently, reduce manual errors, improve traceability, and keep labeling processes more consistent.

Barcode label design is also becoming more important as businesses prepare for evolving requirements around 2D barcodes, GS1 Digital Link, and product traceability. Companies need labels that can support accurate data today while remaining flexible enough for future changes.

The best way to design barcode labels is to build a process that supports both design quality and operational efficiency. That means choosing the right barcode symbology, designing for readability, setting up printers correctly, using reusable templates with variable data, and testing labels before they reach production.

The ultimate barcode label checklist

Before releasing a barcode label to production, ask yourself these questions:

• Is the correct barcode type being used?
• Is the barcode sized properly?
• Are quiet zones protected?
• Is contrast sufficient? 
• Will the label remain scannable in its environment?
• Is the printer setup optimized?
• Has the barcode been tested with production scanners?
• Is the data accurate and coming from a trusted source?

At TEKLYNX, our labeling experts are always here to help if you have questions on the above. Get in touch with our professional services team.

Ready to design better barcode labels?

Designing barcode labels doesn’t have to be complicated. With the right process and the right barcode labeling software, your team can create labels that print accurately and scan reliably.

TEKLYNX barcode labeling software helps businesses design barcode labels, use variable data, leverage native printer drivers, and support evolving barcode requirements. This National Barcode Day is the perfect opportunity to evaluate your labeling process and identify opportunities for improvement before small issues become costly problems.

Ready to improve the way you design barcode labels? Buy barcode label design software or download a free, 30-day trial.

BUY LABEL DESIGN SOFTWARE ONLINE