Comparing robust warehouse scanners
Products
November 7, 2025
Miranda van Tellingen
Typical challenges in warehouse scanning
Warehouses face specific obstacles when it comes to barcode reading, such as:
- Damaged or poorly printed barcodes: barcodes that are dirty, creased, or partially covered.
- Barcodes at a distance or high on shelves: not all scanners can read from far away or at height.
- Slow scanners or workflow delays: poorly performing scanners slow down picking and shipping.
- Wireless connectivity or battery issues: interruptions cause downtime and frustration for staff.
- Incorrect or duplicate scans during peak periods: leads to order errors and higher operational costs.
Understanding these challenges helps in choosing the right scanner for your warehouse.
What makes a handheld scanner effective?
A good scanner provides fast and accurate barcode reading, even in challenging warehouse conditions. The key features are:
- Fast reading capability: a scanner should decode barcodes immediately, even if labels are damaged, poorly printed, or partially covered. This prevents delays in the order process.
- Accurate scanning distance: in warehouses with high shelves or large areas, it is important that the scanner can read barcodes from a distance. Extended range scanners increase efficiency and reduce physical strain on staff.
- Durability: a good scanner can withstand drops, impacts, dust, moisture, and temperature fluctuations. This is crucial for intensive use in logistics environments.
- Workflow integration: the scanner should fit seamlessly into processes such as receiving, picking, and shipping without slowing down the workflow.
Scanner categories in warehouse environments
1. Premium rugged: 24/7 use, high volumes, harsh conditions
- Maximum durability: IP65–IP67, drop-resistant up to 2–3 m or more
- Extended scan range: 0.1 m to 4 m+
- Extensive SDKs and integration options
2. Standard rugged: intensive use, no extreme conditions
- Good durability: IP54–IP65, drop-resistant up to 1.5 m
- Standard scan range: 0.1–2 m
- Solid brand support and robust for normal warehouse conditions
3. Mobile: mobile workflows, fast picking, hands-free use
- Slightly less rugged, often wireless or wearable
- Ideal for pickers and mobile workflows
- Drop-resistant up to ~1 m, IP54
Practical tips for implementation
- Test in the workflow: have employees use the scanners for a day to assess whether performance meets expectations.
- Measure scan speed and error rates: compare before and after replacement to quantify the impact.
- Battery and spare management: essential for wireless scanners; check cables and mounts for wired models.
- Train staff: even the best scanner won’t perform optimally if employees aren’t familiar with it.
- Plan for the future: consider growth, different barcode formats, or changed warehouse layouts.
Optimize your warehouse: choose the right handheld scanner
The right handheld scanner can transform your warehouse: fewer errors, faster workflows, and increased efficiency. At Reverse IT, we work with top brands such as Zebra, Honeywell, Datalogic, and ProGlove, all proven suitable for intensive use, ensuring your organization is ready for today and the future.