How to Choose Between a Barcode Reader and a Vision System in Manufacturing?
1 May 2025
Barcode and DMC Code Reading in Manufacturing: Fixed Barcode Reader or Vision System?
In today’s manufacturing and logistics environment, the reliable and fast reading of barcodes and DMC codes (Data Matrix Codes) is critical. Whether for product traceability, order accuracy, or automated assembly — selecting the right technology can significantly impact your process efficiency.
So which approach is best? A fixed barcode reader, or a machine vision system?
Let’s explore the pros, cons, and practical examples of both.
What’s the Difference?
Fixed Barcode Reader: A specialized device designed to scan one or multiple types of codes at high speed. Typically laser- or imager-based.
Vision System: An industrial camera system with intelligent software that reads codes and performs additional inspection tasks such as positioning, label check, or quality control.
Advantages of a Fixed Barcode Reader
High speed – Ideal for high-throughput environments
Low cost – Cost-effective for basic scanning tasks
Compact integration – Easy to install into tight spaces
Simple setup – Plug & play functionality
Use Case Example:
A beverage packaging line uses fixed barcode readers to scan EAN-13 barcodes on cartons. The labels are always positioned the same, and the process is straightforward.
Disadvantages of a Fixed Barcode Reader
Limited flexibility – Doesn’t perform well with misaligned or damaged codes
No additional inspection – Only scans codes, nothing more
Not suitable for dynamic environments – Not ideal for varying product shapes or code formats
Advantages of a Vision System
Multifunctional – Combines code reading with other inspection tasks
Highly reliable – Even reads damaged, rotated, or hard-to-see codes
Flexible – Supports multiple code formats and product types
Future-proof – Expandable with OCR, AI, label detection, etc.
Use Case Example:
An automotive supplier uses a vision system to read DMC codes on metal parts. The parts are randomly oriented on a conveyor. The system adjusts position, reads the code, and simultaneously checks part geometry for robotic assembly.
Disadvantages of a Vision System
Higher investment – Cameras, optics, and software raise the initial cost
More complex – Requires proper engineering and testing (FAT/SAT)
Ongoing calibration – Regular tuning for lighting and positioning needed
Quick Comparison: Which to Choose?
| Scenario | Fixed Barcode Reader | Vision System |
|---|---|---|
| Fixed position & high speed | ✅ | – |
| Variable position or code type | – | ✅ |
| Poor code quality | – | ✅ |
| Only barcode scanning needed | ✅ | ✅ |
| Barcode + quality inspection | – | ✅ |
| Low budget | ✅ | – |
| Long-term flexibility | – | ✅ |
Why choose a vision system?
In many modern production environments, flexibility is more important than ever. Small batch sizes, product diversity, and high quality standards require more than just barcode reading. A vision system can provide the solution:
Combine identification with quality control
Automate defect detection on multiple levels
Integrate into robot cells or traceability systems
Adapt to changes in products or inspection rules through software updates
Conclusion
Choosing between a fixed barcode reader and a vision system depends on your application. If you need fast and simple code reading in a controlled environment, a barcode reader is likely sufficient. But for versatility, inspection, and future scaling, a vision system is the smart choice.
Need Advice?
At Vision Consultancy BV, we help manufacturing companies make the right technology choices for code reading and quality control. Whether you're considering a simple barcode setup or a complex vision system , we guide you from feasibility study to commissioning.
