Tips for RFID Smart /Encoding EXECUTIVE SUMMARY

Zebra Technologies introduced the first integrated, Accurate RFID encoding is critical to every on-demand radio frequency identification (RFID) deployment. If the printer/encoder does not perform smart label printer/encoder in 2001, and since then, the tag data and item association correctly, the errors we have worked with hundreds of customers around can propagate throughout the entire supply chain. the world who use different RFID protocols, Following the tips described in this white can frequencies, inlay designs and standards. This help you get more from your smart label printing experience has taught us several best practices that system by improving reliability, minimizing operator are applicable to any smart label printing operation. intervention, reducing wasted , preventing encoding and printing errors, and yielding more usable labels per media roll.

RFID SMART LABEL OVERVIEW

Printable RFID tags contain a low-power integrated the label converter must add an extra process to circuit (IC) attached to an antenna and are enclosed space out the inlays prior to encoding or tagging, with protective material (label media) as determined which adds unnecessary overhead to media costs. by the application. On-board memory within the IC stores data. The IC then transmits/receives Passive tags receive all of their power from the information through the antenna to an external reader, external tag reader, allowing the tag to “wake up” and called an interrogator. High frequency (HF) tags use transmit data. Quite frequently, manufacturers antennas made of a small coil of wires, while ultra- optimize tags for long-range and robust read rates, high frequency (UHF) tags contain dipole antennas with the goal of reading hundreds of tags at once, with a matching wire loop. sometimes several meters away. However, a printer/ encoder’s task is unique: The goal is to encode one Depending on the application, users sometimes call specific tag, in the close vicinity of hundreds or even tags transponders or inlays. Technically, an inlay is a thousands of other tags—not an easy task. tag on a flexible substrate that is ready for conversion into a smart label. RFID tags come in many forms and Fundamentals: sizes, some as small as 10 x 10 mm. Traditional RFID How Printers Create Smart Labels printer/encoders often require an inlay pitch of 50 mm Smart label printer/encoders use media that contains or more to ensure accurate data encoding. Pitch is the an RFID inlay (chip and aluminum, copper or silver distance from the leading edge of an inlay to the antenna bonded to a polyethylene terephthalate (PET) leading edge of the next inlay on the printing web. layer) embedded within the label material. The inlay Shipping compliance and immature chip technology ships to the label manufacturer without adhesive originally drove the 50 mm requirement. Most RFID (“dry”), or attached to a pressure- sensitive liner printers available today contain older RF encoding (“wet”). technology designed for legacy applications (e.g., tracking), forcing them to support a minimum “Converted label” processes embed the RFID inlay inlay pitch of only 50 mm. into a self-adhesive paper label. An RFID encoder inside the printer writes pre-determined data to the Pitch depends on the inlay size, and the smallest RFID tag using radio frequency (RF) transmission. inlays today use a 16 mm pitch. Unfortunately, Next, the printer prints barcodes, text and graphics traditional RFID printer/encoders cannot take using the standard thermal printing process. advantage of these reduced-pitch inlays. As a result,

A Zebra Technologies White Paper 2 The EPCglobal organization developed the UHF Gen 2 dominant RFID smart labeling technology for supply standard so users could accurately identify multiple chain applications, industrial automation, asset items at distances not possible with HF RFID tags. management, inventory monitoring, personal ID and The ISO ratified UHF Gen 2 as an international access control. For more information, visit standard for use worldwide. UHF Gen 2 is the www.gs1.org/epcglobal.

Table 1: Passive RFID Standards

UHF HF Protocols EPC Gen 2 (ISO 18000-6C) ISO 15693 ISO 14443 Developed by MIT Auto ID Vicinity read, Proximity read, Source center and EPCglobal, and now developed by developed by maintained by ISO and GS1 ISO/IEC JTC1 ISO/IEC JTC1 RF Transmission Propagating Back Scatter Electromagnetic Inductive Coupling

Frequency 860-960 MHz (Regionally Dependent) 13.56 MHz (Global)

Read Ranges 10+ meters+ 1 meter 0.1 meter

Reader Cost $500-$1500 $100-$1000

Tag Cost ~$0.10 $0.20-$0.50

Memory Storage 96 bits to several Kbits 256 bits to 8 Kbytes Read/write protection, Security Multiple encryption/security features anti-cloning, and no encryption Retail item level, Access control, secure payment, Applications supply chain, asset tracking, , ticketing access control, authentication

SELECTING THE RIGHT MEDIA

Matching media with the printer and application is and—in classic domino effect—the success or failure important to the success of any label printing system of the RFID system depends on meeting this but is critical for RFID smart label printing/encoding. requirement. Smart label material should adequately RFID systems are designed to minimize interference, protect the inlay and not provide potential ensure data integrity and provide maximum read interference, which affects range and reliability. Due range. RFID read range and data integrity depend on diligence with regard to smart label selection can high-quality smart labels. The smart label must reliably make a huge difference on whether an RFID transfer data in a dependable, predictable manner, implementation achieves success or not.

A Zebra Technologies White Paper 3 Select a Printer That Prints and Encodes On-Pitch Avoid Foil and Metal-based Media On-pitch RFID printers encode tags at the same pitch Do not use foil or metal-based label stocks for smart as specified by the inlay manufacturer, thus labels. Metal reflects RF signals and is a leading eliminating the extra process of spreading apart the source of RFID interference. Embedding an RFID inlay inlays prior to encoding. Successful on-pitch printing within a metal or foil label can prevent successful requires printers designed with tight mechanical encoding/reading and severely limits range. Barcode tolerances, advanced RF technology and intelligent label media sometimes use foil and metal-based firmware. On-pitch RFID printers must also support media to enhance barcode performance by providing easy integration with wireless networking, provide a more light reflection. The media provides no such future-proofed path for upgrades as RFID standards benefit for RFID, which is not an optical technology. evolve, and offer flexibility to support various inlay types and smart label requirements. Watch out for Liquids Zebra delivers intelligent RFID printer/encoders that Liquids are the other leading hindrance to RFID accurately and cost-effectively create smart labels system performance. Liquids can absorb RF signals, down to 16 mm of pitch. Zebra printers require no which can severely limit range or prevent tag mechanical changes, additional RF shielding or other encoding/reading altogether. Therefore, label modifications, allowing fast setup and efficient long- placement on liquid products is critical in order to term operations. Embedded firmware automatically achieve successful read rates and distance. In drives the printing/encoding process and provides addition, synthetic media and laminates commonly flexible support for different media label sizes. Zebra used to protect barcode labels from moisture and RFID printers deliver an average of 10 percent cost liquids pose no problems to smart label performance. savings per tag, which is significant when factoring the scale of product movement in the apparel and Storage Temperature other mass-volume retail industries. Smart label media can withstand a wide range of temperatures, so storage temperature is not usually a Match the Chip Position to the Printer/Encoder concern. Performance will remain optimal if storage RFID users should perform testing to find the best temperatures are kept between -60º and +203º F frequency, protocol, inlay manufacturer and design for (-51º and +95º C). their application’s needs. A common mistake is to place a large order for smart labels early on in the Limit Electrostatic Discharge (ESD) testing phase without making sure the media meets ESD dangers are elevated in low-humidity and high- optimization requirements for the chosen printer/ altitude locations. This may seem like a small encoder. In fact, smart label media is often not consideration, but failing to control for ESD can interoperable among different brands of printer/ seriously affect smart label performance and lead to encoders that support the same RFID protocol. more cost and problems during an RFID Therefore, the specific media requires calibration to implementation. Storing media in non-conductive the specific printer/encoder model to ensure proper bags or cartons (cardboard is sufficient) should alignment and encoding. provide sufficient protection against ESD damage. If ESD is a persistent problem, operators may need to The latest generation of printer/encoders support wear anti-static clothing or wear grounding straps like variable inlay placement with adaptive array encoding. those used in other environments containing sensitive Printer/encoder specifications list specific inlay electronic components. manufacturers and label/tag designs that they support. It is critical that the media provider conforms to these specifications when an RFID user designs smart labels to fit an application. In order to verify that the provider followed the specifications, end users should obtain samples or place a small initial order for testing purposes.

A Zebra Technologies White Paper 4 PRINTER MANAGEMENT

Procedures and training, optional printer/encoder Maximize Encoding Success settings and features, and the physical location of the Printer/encoders should perform two tag quality printer/encoder itself all contribute to successful smart checks. The first check, prior to encoding, verifies that labeling. Be sure to give printer/encoders that offer the inlay is functional and can receive data. The configurable error settings and other flexible options second check verifies that data encoded and stored top consideration because they can increase uptime on the chip correctly. Encoding the inlay and printing and minimize operator intervention. the smart label should require only a single pass through the printer/encoder. A key consideration in Centralize Management Tasks facilitating smooth printing/encoding operations is to With the consolidation of operations that is prevalent ensure that the label edge properly aligns so that the in most manufacturing and IT organizations, there is a tag is in proper programmable position for encoding. trend toward centralized management and Avoid the practice of manually aligning labels, which is administration of peripheral equipment, including common in barcoding. Precise positioning is required printers. Enterprise-level middleware and printer to enable the tag for encoding. The best practice is to applications close the gap between label printer- adjust label location through printer/encoder specific support provided by traditional printer utilities commands or through label design software. and the centralized management, configuration and ® control available in general-purpose management For example, Zebra Programming Language (ZPL ) applications. Now, users can manage all their includes the “Label Home” script usable for adjusting networked printers globally from a single desktop the label’s top position. Label design software application and “push” changes to printers as needed. packages also have features to adjust label layout. Some printer/encoders have programmable encoding Other printer management options use a “pull” positions that allow setting the encoding location from networking task. This capability allows IT the control panel or through the printer command administrators to configure and load printer language. Printer/encoders with a self-calibration information on a networked server once, then allow feature—again an optimal choice—can automatically the printers to pull the data as needed. Printers can determine the best encoding position. The latest pull settings, objects and even firmware from a printer/encoder technology supports an RFID centralized FTP server. Administrators can synchronize calibration feature with automatic program position the printers with specific files maintained on a server selection for optimal transponder placement. using several scenarios, such as when the printer powers up, at specified time intervals, both on power Limit Error Messages up and at time intervals, or on command. Inlays fail to encode for a variety of reasons. While it is fairly uncommon, failure of an inlay not to encode on Pick Printer Placement Carefully the first try does not necessarily indicate a problem. Encoding performance can improve simply by Therefore, it is not practical to issue an error message allowing some physical space between the printer/ or shut down the printer/encoder each time there is a encoder and other RF products that share the same failure to encode. Printers can be set to automatically bandwidth. Interference may result if the printer/ retry encoding. When considering the purchase of a encoder is next to or directly above or below other RF smart label printer/encoder, choose one that allows devices. Remember that the printer/encoder itself is a you to adjust the number of encoding retries to shield to outside RF signals. Removing the printer’s program the smart label before sending an error housing or enclosure can compromise the printer’s message. This flexibility will ensure the highest resistance to interference, reducing encoding percentage of yield rates from your media. performance.

A Zebra Technologies White Paper 5 Designate and Segregate Unencoded Labels Use Alerts for Persistent Problems Sometimes rolls of smart label media suffer damage Halting operations should be the last step in an and portions of the roll will fail to encode. Processes escalated response system. There are other options need to be in place to prevent users from applying short of time-consuming system shutdowns. Most damaged or unprogrammable smart labels to items. encoding failures are isolated incidents resulting from Unusable labels should be clearly marked with a a damaged inlay. Consistent failures could indicate a printed “VOID” message. Another option is to stop the larger problem. Users should program the printer/ printing process when an unencoded label occurs. encoder to issue an alert when a persistent problem This prevents further printing until the error is arises. Zebra strongly recommends that end users resolved—an action only recommended in the case of integrate a robust printer and print server persistent problems. management application in their overall RFID architectures. Software-based monitoring and management of RFID printer/encoders can provide alerts and capture statistics on printer/encoder performance to flag problems before they have serious consequences.

ACHIEVING PROPER LABEL PLACEMENT

Many of the best practices of successful smart label Many variables determine the best approach to printing and encoding apply to placing the label on placing labels on packages, cases and . A cases and pallets: comprehensive guide outlining many of these considerations is detailed in a document created by • Proximity to metal and liquid should be avoided. AIM Global’s RFID Expert Group, titled “Proposed • Care should be given to protect the label against Guidelines for the Use of RFID-Enabled Labels in excessive contact. Military : Recommendations for Revision of MIL-STD-129.” Although designed primarily for military • Consideration should be given to how cases are logistics, these guidelines have been coordinated with stacked on pallets to maintain sufficient distance commercial logistics RFID practice so that conveyable between smart labels. goods used in military and civilian approaches can • Conduct testing to determine the optimum smart conform to a common standard as far as possible. To label placement from the bottom of the pallet. For view the document, contact AIM Global. shrink-wrapped pallets, place smart labels on the outside of the wrap. Bands used to hold pallets or wrappers in place should not wrap around the labels.

A Zebra Technologies White Paper 6 CONCLUSION

Businesses across the world print and encode EPCglobal, and a technology sponsor of the former millions of smart labels every year. Most problems Auto-ID Center at MIT, Zebra plays a leading role in that do arise occur because of a few common the development of smart label technology, conditions that are easily resolved. Many problems standards and applications for supply chain and can be avoided entirely by training associates on the business improvement programs. Zebra has provided leading causes of smart label failure, such as due solutions to many RFID early adopters, including diligence in selecting proper media, media handling, suppliers in the Walmart and U.S. Department of and replacing manual printer calibration with auto- Defense (DoD) compliance programs. calibration models. A global leader respected for innovation and Action taken before deploying the system can also reliability, Zebra offers technologies that illuminate save errors and downtime. Care taken early on to organizations’ operational events involving their optimize media with the specific printer/encoder will assets, people and transactions, allowing them to see save valuable time and costs while improving long- opportunities to create new value. We call it the term yields and throughput. Selecting an intelligent, Visible Value Chain. programmable printer/encoder helps optimize operations because the organization can set the unit Zebra’s extensive portfolio of marking and printing to support desired processes for error resolution and technologies, including barcode, RFID, GPS and alert notification. Printer/encoders that offer sensoring, turns the physical into the digital to give programmable encoding positions and imaging operational events a virtual voice. This enables adjustments make it easier to maintain calibration organizations to know in real-time the location, and uptime. condition, timing and accuracy of the events occurring throughout their value chain. Once the Many other usage, environmental and product factors events are seen, organizations can create new value can affect smart label printing/encoding from what is already there. performance. Contact Zebra Technologies to learn more about setting up an efficient smart labeling For more information about Zebra’s solutions, visit system for your organization. As a member of www.zebra.com.

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