Abstract

The forthcoming Sunrise 2027 mandate, initiated by GS1, compels retail and consumer goods sectors to transition from traditional one-dimensional (1D) barcodes to two-dimensional (2D) barcodes at point-of-sale (POS) and point-of-care (POC) systems. This shift necessitates the adoption of QR codes capable of encoding substantially more data, including batch numbers, expiration dates, and pricing, while remaining scannable within the spatial constraints of product packaging. The objective of this research is to determine the smallest viable QR code size that maintains scanability and verification accuracy, considering both the amount of data encoded and the generation method employed.

This study tested QR codes across seven data volumes and three generation methods: Adobe InDesign (vector format), a standard web-based generator (non-GS1), and a GS1-compliant generator. Each QR code was scaled incrementally from 100% to 10% of its original size and verified using a Cognex DataMan 8072V verifier in accordance with ISO 15415 grading standards. Results indicate that QR codes generated via the web-based tools, including GS1-compliant formats, remained verifiable at scales as low as 13%, whereas InDesign-generated codes demonstrated higher minimum scale thresholds.

The findings underscore the importance of barcode generation method, encoded data volume, and QR code design parameters—such as quiet zones and fixed pattern integrity—in achieving optimal readability on packaging. This research offers practical insights for CPG companies preparing for the Sunrise 2027 compliance deadline, enabling informed decisions about QR code implementation within constrained design environments.