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Saturday, June 8, 2013

GUIDE LINES FOR LABEL SOLUTIONS TO DISTILLERIES AND TO THE BOTTLING PLANTS



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Annexure – I GS1 Barcode Standards for Bottles and Cases

GS1 standards in general provide interoperability, flexibility and vendor independence which in turn result in reduction in end product costs to businesses and consumers. These widely implemented standards enable unique and universal identification of products, assets, services, entities/locations, data capture and seamless sharing of supply chain information between trading partners including manufacturers/ suppliers, retailers and consumers. Flow of physical supplies and data sharing/querying also becomes faster, more accurate and seamless across multiple trading partners in supply chains.
GS1 standards works on Identifiers, these identifiers combines with automatic identification technologies like Bar-Codes to establish a connection between the physical entities involved in a supply chain and their related information.

Broadly, there are two types of identifiers:
1.      GS1 Identification key, For e.g. GTIN, Batch #, Mfg. Date, Unique Serial #,
2.      GS1 Application Identifier, For e.g. (01) for GTIN, (10) Batch #, (11) Mfg. Date, (21) Unique Serial
#

Based on the symbol used to encode data, GS1 bar-codes can be categorized into two broad categories:

1 GS1 barcodes with 1D/linear symbols which include:
  European Article Number ( EAN) /Universal Product Code (UPC)
  GS1 DataBar
  GS1-128
  Interleaved 2 of 5" (the Barcode Symbology used) and 14 digits (the length of the container symbol (ITF-14)

2 GS1 BarCodes with 2D symbols which include:
  GS1 DataMatrix
  GS1 composite component

As per project requirement, 1D GS1 128 barcode symbology shall be used at case/case level and 2D GS1 Data matrix symbology shall be used at Bottle level/Mono Case/Small Case







Data Structure

GTIN 14 Data Structure

Extension
Digit
Company Prefix                                          Item Reference
----------------------------------------         -------------------------------------------
Check Digit
N1
N2
N3
N4
N5
N6
N7
N8
N9
N10
N11
N12
N13
N14
Company Prefix

It consists of countrcode and Company code registered with GS1.  Country Code is 890 for
company registered with GS1 India office.

SSCC (Serial Shipping Container Code) The GS1 identification key used to identify individual logistic Unit. The key is comprised of an Extension digit, GS1 Company Prefix, Serial Reference, and Check Digit.’

SSCC Data structure

Application identifier
Extn
Digit
Company Prefix                                                            Serial Reference
-------------------------                      ---------------------------------------------------------
Check
Digit
00
N1
N2
N3
N4
N5
N6
N7
N8
N9
N10
N11
N12
N13
N14
N15
N16
N17
N18


Application identifier (00) indicates the data field contains an SSCC.

Extension Digit is used to increase the capacity of Serial reference No. with SSCC. It ranges from 0-9.

GS1 Company Prefix A globally unique number assigned to a GS1 member company

Serial reference A global unique Number assigned by company.

Check Digit A modulo-10 number calculated across the preceding digits to ensure data integrity.

Check Digit
Check  Digit  is  computer  check  digit  which  makes  sure  barcode  is  correctly  composed.  This calculation is done by using Modulo 10 algorithm.

Here is how a mod10 check digit is calculated:

1 For this example, we will use a barcode containing the data 12345678912. Starting from the left side of the bar code, add together every other digit, ignoring the check digit. Add the first, third, fifth, seventh, ninth, and eleventh digits:

1+3+5+7+9+2=27

2 Multiply the result from step 1 by 3:

27*3=81

3 Add together the remaining digits. Add the second, fourth, sixth, eighth, tenth, and twelfth digits:

2+4+6+8+1=21

4 Add the results of steps 2 and 3:

81+21=102

5 Find the minimum number which, when added to the result from step 4, will generate a number that is evenly divisible by 10:

102 + n = 110 n = 8

The number 8 is the mod10 check digit for this arrangement of digits.










Case Barcode
Implementation Guidelines for GS1 -128 1D Barcode at Case Level

At case/case level, two barcodes following GS1 128 Barcode symbology shall be printed on a single label to be pasted on each case/case by the distiller.

a)   The first barcode will encode GS1 GTIN number, batch number, and best use before date.

Attribute
Description
Value
Size(N-numeric, AN-Alpha Numeric)
Application identifier
To Identify GTIN Number
01
N2
GTIN
Indicator + Company Prefix + Item
Number+ Check Digit

N14
Application identifier
To identify Batch number
10
N2
Batch Number
A unique Number assigned by
Distiller for a batch

AN7
Application identifier
To identify Manufacturing Date field
11
N2
Manufacturing
Date
Manufacturing Date of liquor
Date shall be in
(YYMMDD)
format
N6
Application identifier
To identify Best before date field
15
N2
Best before
Date
Expiry date of liquor
Date shall be in
(YYMMDD)
format
N6


b The second Barcode will encode unique serial number (SSCC Serial Shipping Container code) of each case up to 18 Digits.
Attribute
Description
Value
Size(N-numeric, AN-Alpha
Numeric)
Application identifier
To identify Data filed as SSCC
00
N2
SSCC
Unique Serial shipping Container
Code downloaded from ESCIMS

N18




First bar-code structure at case level:
This bar-code will have GTIN number (a unique product code for case), batch number and expiry date.
AI
GTIN-14
AI
Batch
Number
AI
Manufacturing
Date
AI
Best Before
Date

Extension
Digit
(1 digit)

Country
Code

(3 digits)
Company
Prefix +

Item Reference Number(9 digits)
Check
Digit

(1 digit)





YYMMDD
01
08902967201905
10
0000518
15
111010
15
000000

ABC Company Limited registered in GS1 India. The Components of GTINs are follows:
Extension Digit 0
Country Code 890
Company Code 2967
Item Reference 20190 Director`s Special Black Whisky 750ml case pack
Batch Number 0000518
Manufacturing Date 111010 in (YYMMDD format) - 10-Oct-2011
Best Before Date 000000 (It will be used in case of beer otherwise it will be zeros for other liquors)

Second bar-code structure at case level:
SSCC (Serial Shipping Container Code) to identify individual case uniquely.

Application Identifier Code
Serial Shipping Container Code (Unique Serial Number)

(18 digits)
00
089029670100012345
Extension Digit 0
Country Code 890
Company Code 2967
Unique Serial Number 010001234 Uniquely identification of case – It must be unique and unique serial number must be assigned from downloaded serial number from ESCIMS.







Bottle Barcode
Implementation Guidelines for GS1 2D Data Matrix Barcode at Bottle Level/Mono Case or Small case (secondary packaging) of 60 ml bottles

At Bottle level/Mono Case or Small Case, 2D GS1 Data matrix symbology shall be used encoded with
GTIN and unique serial number provided by Distiller.

Attribute
Description
Value
Size(N-numeric, AN-Alpha Numeric)
Application identifier
To identify GTIN Number
01
N2
GTIN
Extension Digit + Company Prefix +
Item Number+ check digit

N14
Application identifier
To identify unique serial number
21
N2
Serial number
Unique Serial Number downloaded form ESCIMS for GTIN/SKU

N10


Bottle/Mono Case/Small Case Barcode Examples

Application
Identifier
Code
GTIN-14
Application
Identifier
Code
Unique Serial Number

Extension
Digit
(1 digit)

Country
Code

(3 digits)
Company Prefix +

Item Reference
Number

(9 digits)
Check Digit

(1 digit)

(10 digits)
01
08902967200905
21
0000000123

ABC Company Limited registered in GS1 India. The Components of GTINs are follows. It includes
Unique Serial Number:
Extension Digit 0
Country Code 890
Company Code 2967
Item Reference 20090 Director`s Special Black Whisky 750ml
Unique Serial Number 0000000123 It must be unique and unique serial number must be assigned from downloaded serial number from ESCIMS for a batch.




Technical Specifications for Distillery

The quality of barcode implementation shall have an impact at various points of the supply chain in terms of readability of the barcode. It is important that barcode complies with GS1 standards and the technical specifications suggested in this section.

Barcode Specification
Bar coding is a Data Encoding & Capture mechanism. It is a way to rapidly, accurately and efficiently gather information and transmit it to a computer.

Case – 1D Barcode Specification
Two linear 1D barcodes are recommended for tracking the cases using GS1 128 symbology.

1 First barcode contains following information:
a)   AI (01) GTIN – 14 digits
b AI (10) Batch Number 7 Alphanumeric
c)    AI (11) Manufacturing Date 6 digits in YYMMDD format d AI(15) Expiry Date 6 digits in YYMMDD format

2 Second barcode contains:
a)   AI (00) Serial Shipping Container Code (SSCC) – 18 digits SSCC will be downloaded from ESCIMS when requesting for barcode sequence number while scheduling of production for a batch and it must be unique.

Note:
  l
Expiry Date and of second barcode SSCC will also be printed in human readable text as per the statutory requirements.
  Ipi
readable text.

Bottle/Mono Case/Small Case 2D Barcode Specification
2D Data Matrix symbology is recommended for tracking the bottles and its mono case or small case in case of secondary packaging of 60 ml bottles, where applicable.

2D barcode contains following information:
a)   AI (01) GTIN – 14 digits
b AI(21) Unique Serial number

For secondary packaging, separate 2D Barcodes will be used for printing and pasting on secondary case. These 2D barcode GTIN and unique number will be downloaded from ESCIMS.

All above information GTIN and unique serial number will also be printed in human readable text. Batch number and manufacturing date will be printed on bottles labels same as currently being printed on production line.

Note:
a Regulatory  Requirement  such  as  Batch  Number  and  Manufacturing  Date  will  not  be encoded in 2D barcode.
b Downloaded unique serial number from ESCIMS will be used and must be unique for bottles/mono cases.

c Unique Serial Number of bottle and its mono case must be same.
d)     Downloaded unique serial number of secondary case of 60 ml bottles will be used and must be unique for secondary case.

Barcode Dimension
Minimum  sizes  which  are  readable,  are  recommended  for  barcode  dimensions  of  1D  and  2D
barcodes. These can easily be scanned by recommended barcode scanners.

Case – 1D Barcode Dimension
Contents of 1D barcode are described in Section 2.1.1.

First Barcode
Mil Size: 10 Mils
Barcode Dimension 2.85 (Length) x 0.40 (Width)
aBy Hand Held Terminal 4” – 8

Second Barcode
Mil Size: 15 Mils
Barcode Dimension 2.27 (Length) x 0.40 (Width)
Read Distance - By Hand Held Terminal 3” – 9.5”

Label Size 4’’(Length)x4’’(Width) for both case barcodes in one label
Paper Type
  Temper Evident Label recommended resin ribbons for Thermal Transfer printing
Sample Case Barcode:

Bottle/Mono Case/Small Case 2D Barcode Dimension
Contents of 2D barcode are described in Section 2.1.2.

Mil Size: 15 Mils
Barcode Dimension 0.24 (Length) x 0.24 (Width) Read Distance – By Hand Held Terminal 2” – 6Label Size 2’’(Length) x 0.6’’(Width) sticker
Paper Type
  Tee recommended resin ribbons for Thermal Transfer printing

Sample 2D barcode:

Label Size

Case – 1D Barcode Label Size
The recommended label size for 1D barcode would be 4 (length) X3 (Width) or 4 (Length) x 4” (Width) with 10 mil Bar Code Size for the first bar code and 15 mil Bar Code Size for the second bar code so that human readable text and other text if required can also be accommodated. The size of
1D bar code is more or less same for all cases as there is no space consideration.

Bottle/Mono Case/Small Case 2D Barcode Label Size
The recommended label size for 2D Barcode would be 2’’ (Length) x 0.6’’ (Width) on sticker with 15 mil Bar Code Size.

Each distillery has to ensure all parameters of 2D barcode have been taken care for all current and future product launches in new packaging.

Parameters for 2D Barcodes:
1 Barcode Dimension as described in Section 2.2.
2 Label Size - as described in Section 2.3.
3 Read Distance - as described in Section 2.2.
4 Scanning on Low Visibility Should work fine on the low visibility also.
5 Paper Type Water proof, self destructive, smudge proof Should preferably be Temper
Evident Label.
6 Glue Quality
7 Life of Ink printed by printer It should be 1 to 2 years.
8 Quality of Case Paper
PCR  (Print Contrast Ratio) Scanner should have minimum PCR of 25% so that it can read poorly printed barcode with low contrast between foreground and background.





Annexure – III Scanner Specifications

2D Data Matrix is read by imaging cameras devices. The principle is based upon first capturing the image of the symbol and then analyzing it. This is different technology from the one used by many of the laser scanners for reading the linear barcode symbol. A linear symbol can be read by a single laser beam passing across the length of the symbol. However, to read Data Matrix symbol requires the entire image to be read in both the X and Y axis. 2D is considered to be having better readability compared to 1D. It can be read from any angle and side of scanning. In case of any minor damage to the 2D bar code, the readability is still ensured.


Scanners will be used for scanning the bottles/case during packaging of bottles and dispatch while uploading the cases on truck.


Distiller has to upload barcodes information of 1D for case and 2D for bottles in XML or excel format through ESCIMS portal.


It is to be understood by the Distiller that the product features and specifications of the devices recommended in the document for scanners are for reference only. Distillers have to decide and discussed with vendor to procure and meet the requirement of 1D and 2D barcodes scanning.


To ensure the reliability of barcode scanning, it is recommended that scanner should possess following features:

  Comprehensive data capture options 1D, 2D, image capture
  Supports for all major 1D, PDF, postal and 2D symbologies
  High Resolution of camera
  Rugged Design
  Tempered Glass exit window
  Multiple on-board interfaces and universal cable
  Omni-directional scanning, wide working range
  Comprehensive connectivity options including wireless, cordless and corded
  High resolution high contrast color QVGA display


A good quality hand held digital image or mobile scanners (HHT) capable of scanning GS1 barcodes
(1D and 2D barcodes) possessing above mentioned features should be used.






Annexure III - Printer Specification

Broadly, the packaging of Indian Made Foreign Liquor (IMFL), Country Liquor and Beer bottles will be done in three stages in bottling lines:
1 Primary Packaging
2 Secondary Packaging
3 Tertiary Packaging

Primary Packaging
Distillers are currently pasting pre-printed labels on bottles manually or printing information like batch number and manufacturing date through inkjet printer on glued labels or through Thermal Transfer Printer (TTO) on self adhesive labels.

For printing 2barcode with other texts in human readable form like GTIN and Unique Serial Number, Batch Number and Manufacturing Date, the following printers are recommended for inline printing on online conveyors.
1 Thermal Transfer Printers (TTO) for self adhesive labels
2 Inkjet Printer for glued labels
3 Print and Apply (PA) for Metal Can


In case of offline printing Thermal Transfer printer for self adhesive labels with resin ribbon shall be recommended.

It is to be understood by the Distiller that the product features and specifications of the devices recommended in the document for printers are for reference only. Distillers have to decide and discuss with vendors to procure and meet the requirement of 1D and 2D barcodes printing.



S. No.


Product


Description


Pack Size

Coding
Media
Current Coding Method

Coding
Application
Proposed
2D  Coding
Method
Proposed   2D Coding Application
1.
IMFL
IMFL i.e. Whisky, Vodka, Rum, Gin and
Wine are packed in Glass
/ Plastic
Bottles.
175ml, 375ml,
750ml & 1000ml
Self
Adhesive
Thermal
Printers to
code
Various Information like Batch
No.,     Mfg., MRP etc.
Online Labelling Machine,



Manual
Stamping
Thermal Transfer Printers (TTO)
Online/Offline
Labelling Machine- TTO (Self Adhesive Labels)
Glued
Labels
Inkjet
Printer to
code
Various Information like Batch
No., Mfg., MRP etc./
Offline Label Stacker,

Online / Offline
Conveyors,

Manual
Stamping
Inkjet Printer (IJP)
Online/Offline Conveyors- IJP (Glued Labels)
2.
Country
Liquor
Country Liquor is packed in Glass /
Plastic Bottles and Pouches
175ml, 375ml,
750ml
Self
Adhesive/

Glued
Inkjet Printer to code Various
Information
Manual
Stamping
Thermal Transfer Printers (TTO)

Online/Offline
Labelling Machine- TTO (Self Adhesive



S. No.


Product


Description


Pack Size

Coding
Media
Current Coding Method

Coding
Application
Proposed
2D  Coding
Method
Proposed   2D Coding Application




Labels
like Batch
No., Mfg., MRP
etc.


Labels)
Offline
Label
Stacker,
Online / Offline
Conveyors,
Manual
Stamping
Inkjet Printer (IJP)
Online/Offline Conveyors- IJP (Glued Labels)
Direct
Printing for
Pouches
To code Various Information
like Batch
No., Mfg.,
MRP
etc.
Manual
Stamping
Thermal Transfer Printers (TTO)
Pouch Packaging Machine-TTO (Pouches)
3.
Beer
Beer is packed in Glass Bottles
/
330ml,500ml,650 ml
Self
Adhesive/

Glued
Labels
Inkjet
Printer /

to code
Various
Information like B. No., Mfg., MRP

etc.
Online on Bottle filling Line

Offline
Label
Stacker,


Online- Conveyors
Thermal Transfer Printers (TTO)
Online/Offline
Labelling Machine- TTO (Self Adhesive Labels)
Inkjet
Printers
Online/Offline Conveyors- IJP (Glued Labels)
Metal
Cans
Self Adhesive Stickers
To code
Various
Information like B. No., Mfg., MRP
etc.
Print and
Apply (PA)
Online/Offline
Metal Cans - PA (Stickers)

Secondary Packaging
Distillers are packaging bottles in mono cases manually or shrink wrapped in case of beer for small bottles/metal cans. Information such as manufacturing date and MRP are being directly printing on mono  case  or  pasting  labels  through  inkjet  printer  or  manual  stampinoonline  or  offline conveyors.


For printing 2D barcode with other texts in human readable form like GTIN, Unique Serial number, batch number, manufacturing date and MRP, the following printers are recommended for inline printing on online conveyors.
1 Inkjet Printer for directing printing or on glued labels
2 Print and Apply (PA) for shrink wrapped of small beers and metal can


In case of offline printing Thermal Transfer printer for self adhesive labels shall with resin ribbon be recommended.



S. No.


Product


Description

Pack
Size

Coding
Media
Current Coding Method

Coding
Application
Proposed
2D    Coding
Method
Proposed   2D Coding Application
1.
IMFL
IMFL i.e. Whisky, Vodka, Rum, Gin and
Wine are packed in
Outer Cases
Single
Unit
Direct
Coding,

Labels and Manual Stamping
Inkjet Printer to code Various Information like B.
No.,      Mfg., MRP etc.
Online         / Offline Conveyors
Inkjet Printer (IJP)/

Print & Apply
Machine
(PA)
Online/Offline
Conveyors
2.
Country
Liquor
Country Liquor is packed in Glass /
Plastic Bottles are not packed in Outer
Cases
NA
NA
NA
NA
NA
NA
3.
Beer
Beer (Small Bottles
/ Metal Cans) are sometimes Shrink Wrapped.
2,    4,
6 etc
Direct Coding, Labels
Inkjet Printer to code Various Information like B.
No.,      Mfg., MRP etc.
Online         / Offline Conveyors
Print            & Apply Machine
(PA)
Online/Offline
Conveyors

Tertiary Packaging
Distillers are packaging bottles into shipper case manually or shrink wrapped tray in case of beer for small bottles/metal cans. Information such as batch Number, manufacturing date etc are being directly printing on shipper case or on pasting labels through inkjet printer or manual stamping on online or offline conveyors.
For printing 1D barcode with other texts in human readable form like GTIN, Batch Number, Manufacturing Date and Serial Shipping Container Code (SSCC), the following printer is recommending for printing.
1 Print and Apply (PA) for Shipper Cases in case of inline printing on online conveyor
2 Thermal Transfer Printer in case of offline printing



S. No.


Product


Description

Pack
Size

Coding
Media
Current Coding Method

Coding
Application
Proposed
1D    Coding
Method
Proposed   2D Coding Application
1.
IMFL
IMFL  is  packed  in
Shipper Cases
12 or
24
etc.
Direct
Coding
Inkjet
Printer,
Manual Stamping to code
Various Information like B. No.,
Mfg.,    MRP
etc.
Online         / Offline Conveyors
Print            & Apply Machine
(PA)
Online/Offline
Conveyor
2.
Country
Liquor
Country Liquor is packed in Shipper
Cases
12 or
24
etc.
No Coding / Direct
Coding
Inkjet
Printer,
Manual Stamping to code
Various Information like B. No.,
Mfg., MRP
etc.
Online         / Offline Conveyors
Print            & Apply Machine
(PA)
Online/Offline
Conveyor




S. No.


Product


Description

Pack
Size

Coding
Media
Current Coding Method

Coding
Application
Proposed
1D    Coding
Method
Proposed   2D Coding Application
3.
Beer
Beer is packed in
Shipper Cases /
Shrink wrap Trays
8, 12,
14,
16 etc
Direct
Coding
Inkjet
Printer,
Manual Stamping to code
Various Information like B. No.,
Mfg., MRP
etc.
Online         / Offline Conveyors
Print            & Apply Machine
(PA)
Online/Offline
Conveyor


In  view  of  transit  damages,  it  is  recommended  that  the  case  quality  is  improved  to  avoid  re- packaging instances. Besides, handling of cases has to be improved.


Annexure – IV Tamper Evident Labels

Material Description: Specifically designed for corrugated boxes having rough surface, dust and high moisture content. It is highly effective for manual application of the labels or where no applicator being used. Also, where the storage of boxes is improper so that label does not peel off.

The evident properties are derived from top layer, which is semi gloss white, co-extruded film consisting of an expanded polystyrene layer with a clear polystyrene surface film. The top coat is highly receptive to thermal printing as it is having matt finish. The total calliper of material is being
0.145mm with difference of plus minus 10%.

Adhesive:
A  highly  aggressive  permanent  rubber  based  adhesive  featuring  high  initial  tack  and  excellent ultimate bond strength to a wide range of substrates. The Adhesion is equally effective for Manual as well as Auto Application of the Labels.


Minimum Application Temperature: + 5o C
(The minimum temperature at which the label can be applied and will adhere)


Service Temperature Range: - 20o C to + 70o C
(The temperature range to which the label can be exposed after the adhesion bond to the substrate has been formed)


Application:
Typical applications include product identification labels on various types of corrugated boxes and glass containers. The moderate internal strength of the face allows the product to be used as a tamper evident label. The label can also be used as a shrinkable seal by using heat after application. Adhesive is in compliance with FDA recommendations, where incidental contact between food and adhesive may be possible.


Conversion:
This product can be printed in the usual printing technologies; for variable information printing thermal transfer and inkjet printing can be used. It’s recommended to use Resin Ribbons for Thermal Transfer Printing for better outcome.
Customized security cuts are also advised according to label size, to enable a better view of temper evidence if label is tried to be peeled off from the substrate.
It has also been observed that the bigger the label sizes provide better adherence due to larger bonding area and increase the material effectiveness.
Material should be handled with great care; rough handling may leave permanent impressions in the relatively soft face stock.


Shelf Life: Two years when stored at 22C