When to Use GS1 DataBar Expanded Stacked: Timing and Implementation Guidance

Choosing the right moment to implement GS1 DataBar Expanded Stacked makes the adoption smoother and ensures the barcode delivers value. This article explains the practical decision points and timelines for using DataBar Expanded Stacked across product life cycles and supply chains.

When space is constrained at design or labeling stages

If a product’s primary or secondary packaging lacks horizontal space for a GS1-128 or a long linear barcode, consider DataBar Expanded Stacked during the packaging design phase. This is the most natural time to specify symbology: artwork, dielines, and print specifications are being finalized, so the barcode can be integrated without last-minute changes.

When multiple GS1 Application Identifiers are required

Use DataBar Expanded Stacked when you must include several AIs (GTIN, expiry, lot, serial, weight) on the product itself. This often arises when regulatory, retailer, or internal traceability needs require that data at the item level rather than only on cartons or cases.

When preparing for regulatory compliance or recalls

Adopt DataBar Expanded Stacked if regulations or industry standards demand unit-level traceability. For example, pharmaceutical, food safety, or medical device requirements may specify batch and expiry information at dispensing. Implementing the DataBar as part of a compliance project ensures systems and workflows are ready to capture and use the data for recalls or safety alerts.

During product launches or SKU changes

When introducing a new SKU—or updating an existing one with new formulations or packaging—is a practical time to switch to DataBar Expanded Stacked. The launch process includes artwork approvals, supplier coordination, and verification testing, so adding a barcode change fits naturally into the project timeline.

When migrating systems for better traceability

Organizations upgrading POS, ERP, WMS, or traceability platforms should consider aligning those technology changes with barcode updates. If a new system can handle multiple AIs more effectively, converting to DataBar Expanded Stacked at the same time reduces rework and ensures end-to-end visibility.

When to pilot and test

1. Start with a pilot SKU: Choose a small number of SKUs representative of the packaging types and supply chain steps you need to cover.
2. Print test runs: Work with your label printer to simulate production printing and verify symbol quality on actual substrates.
3. Conduct decode testing: Test with the scanner models used in stores, warehouses, and distribution centers to ensure consistent reads.
4. Verify integration: Confirm POS, WMS, and ERP can accept and store the scanned AIs, and that reports and business rules use them correctly.

When not to implement

• If your operational environment relies entirely on very old scanners that lack support for stacked symbologies—and upgrading is not possible—DataBar Expanded Stacked may not be practical.
• If you do not have the internal systems to capture and benefit from the additional AIs, implementing the symbol adds little value. Ensure system readiness prior to rollout.

Typical implementation timeline

1. Planning and requirements (2–4 weeks): Define AIs, sizing, placement, and system impacts. Engage stakeholders—retailers, IT, packaging, and quality teams.
2. Artwork and print setup (2–6 weeks): Update label artwork, set up print files, and create verification plans with printers.
3. Pilot printing and verification (1–4 weeks): Print samples, verify with scanners, and adjust parameters as needed.
4. System integration and testing (2–8 weeks): Update POS/WMS/ERP mappings, test scans end-to-end, and resolve data flows for recalls and reporting.
5. Rollout (variable): Phased rollout by SKU, supplier, or geography to manage risk and collect feedback.

Checklist for a successful timing and implementation

• Confirm which AIs are required and why.
• Coordinate with retailers and distribution partners on scanability and acceptance.
• Test print quality on final substrates and in final packaging formats.
• Verify scanners used in-field can decode the stacked DataBar reliably.
• Ensure IT systems can parse and store the AIs and use them in business rules.
• Document rollout steps and provide training for store and warehouse staff.

Summary



Use GS1 DataBar Expanded Stacked when packaging design constraints, compliance needs, or business processes require multiple AIs at the item level, and when your scanning and IT environments support stacked symbologies. The best times to implement are during packaging design, SKU launches, or IT migrations when stakeholders are already coordinating changes. Pilot thoroughly, verify with real devices, and ensure systems are ready to capture and act on the encoded data for a smooth, value-driven deployment.