Shortcuts
- What are barcode scanners?
- How does an automatic scanning gate work?
- Where are barcode scanners used?
- What types of industrial scanners are used at security checkpoints?
- Specialized scanning gates
- Scanning Gate Project: From Analysis to Launch
- What are the benefits of implementing a barcode scanner?
- Highlights
What are barcode scanners?
In many logistics and manufacturing processes, manually scanning each label can be replaced with a solution based on industrial, stationary barcode scanners. These systems automatically recognize markings on packages, cartons, pallets, components, and other items moving through a process point.
A scanning gate is a complete automatic code-reading system, not just a single scanner mounted above a conveyor belt. The solution may include mechanical components, several stationary industrial scanners, optics and mirrors, additional sensors, control systems, software, and integration with automation and IT systems.
The layout of the equipment is designed so that the code can be read from one, several, or all required sides of the object. The system can recognize barcodes and 2D codes, DPM markings applied directly to the product, as well as text using OCR. It can also save images and log “no-read” events—situations in which a mark could not be correctly recognized.
How does an automatic scanning gate work?
An object enters the reading zone, the readers scan it, and the data is then sent to the controller and the monitoring software. The system can compare the data against the database, verify the product’s compliance, log the event, or send a command to the sorter or conveyor.
The gate can integrate with systems such as WMS, WCS, MES, ERP, SAP, or PLC controllers, among others. As a result, scanning is not a separate operation but automatically triggers subsequent actions. Goods can be routed to the appropriate zone, put away in the warehouse, linked to a production order, or held for inspection.
Where are barcode scanners used?
The most common solution is a system mounted above or around the conveyor. In a simple application, scanning from a single direction is sufficient. In more demanding processes, scanning tunnels are used to identify codes from multiple sides of a package, regardless of its orientation.
Gates are also used in receiving, shipping, loading, and unloading areas. A pallet can be identified as a forklift or hand truck passes through a designated zone.
The system reads labels from large cardboard boxes, logistics containers, and entire pallet units without requiring the operator to stop and manually use a barcode scanner. Solutions of this kind are used, among other things, in warehouse logistics, package sorting, manufacturing, and shipping processes.
The system can be stationary, mobile, adapted to different load heights, or equipped with a mechanism that moves the scanning module vertically. The following factors are important: the size and speed of the objects, the location of the labels, the number of codes, their quality, the type of surface, and the conditions at the installation site.
What types of industrial barcode scanners are used at security checkpoints?
Compact applications utilize stationary short-range scanners. They are ideal for production stations, machinery, packaging lines, and small conveyors. More demanding processes utilize mid-range scanners with higher resolution , processing power, and enhanced optics and lighting. They are designed for high-speed lines, challenging codes, DPM, OCR, and traceability systems.
Logistics tunnels, sorting facilities, and systems serving large facilities require advanced, high-resolution scanners. These scanners enable multi-angle reading of codes on packages, cartons, and pallets moving at high speeds. The selection of devices should be based on application testing, not solely on catalog specifications.
Specialized scanning gates
An example of an advanced application is BHS systems at airports. Integrated scanning stations, tunnels, and sorting gates identify baggage, track its flow, and direct it to the appropriate logistics stream. Such systems utilize laser and vision-based solutions, as well as RFID technology.
Another example is traceability systems for the tire industry. A multi-head scanning frame can read markings on the top, side, and bottom of the tire—even on black rubber, in low-contrast conditions, and with varying tire orientations. This supports traceability, sorting, quality control, and internal logistics.
The gate can also be upgraded with a machine vision system. Vision cameras not only read codes but also check product completeness, label accuracy, the presence of components, dimensions, positioning, and visible defects. Automatic code reading can therefore be combined with vision-based quality control in a single station. In this area, we collaborate with PEKAT VISION, a provider of industrial vision inspection solutions.
Scanning Gate Project: From Analysis to Launch
An automatic code-reading solution is developed based on an analysis of a specific process. At HKK Group, we design the entire system: the structure, the placement of scanners and sensors, the control system, communication with higher-level systems, and the software. We select the technology based on the reading range, line speed, type of codes, and the required identification accuracy.
The scope of implementation may include application testing and proof of concept, structural construction, equipment configuration, installation, integration, commissioning, acceptance testing, and support during the start-up phase. Our engineers also perform on-site work for complex logistics and industrial projects that require multi-stage operations.
We rely primarily on solutions from global leaders Datalogic and ZEBRA. We work directly with manufacturers of automatic identification technology. This allows us to create a cohesive, efficient, and stable system tailored to real-world operating conditions.
What are the benefits of implementing a barcode scanner?
Automatic scanning reduces the number of manual steps, shortens the identification time, and minimizes the risk of errors. It also provides real-time data on the flow of goods, greater transparency in processes, and the ability to respond quickly to a missing scan or product nonconformity.
A well-designed gate becomes an integral part of logistics or manufacturing automation. It can support a simple identification point, a multi-sided scanning tunnel, a pallet passage zone, or a specialized industry-specific system. It is crucial that the solution be designed specifically for the process and then integrated, commissioned, and tested.
