Business leaders are constantly seeking ways to speed and streamline operations in today’s fast-paced warehouse environment—and scanning technology is often a prime focus when they launch a search for new tools that can help warehouse associates pick up the pace and work more efficiently. From wearable versions to equipment-mounted solutions, today’s high-tech barcode scanners can help speed picking and returns processing and expedite shipping across retail, manufacturing, and distribution operations.
And with the global barcode scanner market set to increase at a compound annual growth rate of more than 8% from 2023 to 2030, success stories are emerging across the logistics landscape. According to the India-based research firm Cognitive Market Research, the global market for barcode scanners will reach $16.84 billion in the next five years, with growth expected in all regions of the world. Recent projects from wearable scanning solution provider ProGlove and logistics tech firm Zebra Technologies show just how fast the trend is spreading.
HIT THE GROUND RUNNING
Like many retailers, athletic footwear and apparel company ASICS relies on speed and flexibility to ensure smooth deliveries to its customers around the world. To that end, the Japanese firm—whose name stands for “Anima Sana in Corpore Sano,” or “A healthy mind in a healthy body”—has long been testing new technologies in its distribution centers (DCs), including barcode scanning projects at two DCs in Europe, one in Germany and one in France.
The company recently partnered with ProGlove to implement wearable scanners for picking fast-moving items and processing returns in both facilities—largely to help improve consistency, which was suffering due to rising labor costs, turnover, increasing demand, and supply chain issues. The DCs support both ASICS stores (B-to-B) and online consumer orders (B-to-C). The company previously used conventional handheld barcode scanners to get those jobs done, but they were heavy and awkward to manipulate—and slowed the workflow while increasing workers’ risk of repetitive stress injuries.
Company leaders wanted a solution that would speed picking and returns and put a safer, more ergonomic tool in workers’ hands. They chose ProGlove’s Mark scanners, which attach to an adjustable hand strap that’s worn like a glove.
“Workers can move freely while scanning, without the clunky, awkward motions that come with traditional handheld devices. That might seem like a small detail, but when you’re dealing with thousands of items a day, it adds up to significant efficiency gains,” explains Patrick Blitz, principal product manager, device management and analytics at ProGlove. “On top of this, in tasks like returns—where you’re unpacking, inspecting, and storing items—having both hands free makes the process so much faster. Additionally, ProGlove scanners reduce physical strain in the warehouse. Instead of having to lift bulky pistol-grip scanners hundreds of times a day—which results in over 1.5 tons of additional weight lifted over the course of a day—shop floor workers can rely on a lightweight scanner worn comfortably on their hand.”
In addition to the scanners, ASICS is using ProGlove’s Gateway connectivity platform, which ensures that data from the scanners flows into the facilities’ warehouse management systems (WMS). The platform aggregates that data to provide insights and analytics that help managers identify and understand where process errors and inefficiencies may be occurring.
ASICS has made double-digit gains in efficiency and worker performance at both DCs since implementing the ProGlove solution in 2020.
“Over the past few years, ASICS has seen significant improvements in efficiency—27%, to be exact. Beyond this, what truly stands out to me is how these tools have transformed the experience for employees,” Blitz says. “With a 15% to 20% boost in individual performance, workers are accomplishing more under less physical strain. By speeding up processes and reducing errors, the technology has lightened the workload for warehouse staff, enabling them to focus on higher-value tasks and work more efficiently.”
And it’s also helping to attract and retain workers. Both ASICS and ProGlove leaders say the use of innovative technology that makes work easier appeals to a wide swath of workers—and word spreads when companies offer those kinds of benefits.
“Employees know when a warehouse has adopted superior technology, and it ‘feeds’ word of mouth, which is an incredibly strong influencer,” company leaders said in a separate statement describing the project. “This is how employee-centric technology gives ASICS a decisive edge as an employer.”
RECIPE FOR SUCCESS
Leaders at bakery supply company Zeelandia likewise needed a better barcode scanning solution—in this case, in their European DC, where wired, forklift-mounted scanners were proving inefficient and costly. They turned to industry technology developer Zebra Technologies for a wireless solution that is speeding deliveries and has trimmed maintenance costs.
The Netherlands-based company sells ingredients to industrial bakeries as well as small and mid-sized outlets throughout Europe and around the world. Products arrive at the DC in bulk and are then repackaged and shipped to customers.
Forklifts are used for both inbound and outbound processes at the DC: Incoming pallets are scanned by forklift-mounted barcode scanners; the information captured is then transmitted to the facility’s IT system, which tells the driver, via a terminal, where to deliver the pallets for storage in the warehouse. For outbound operations, the process works in reverse: The system directs forklift drivers to a retrieval location, where they scan the pallet’s barcode and prepare it for its next move in the DC.
But there was one big problem with the previous system: The wired scanners couldn’t stand up to the rough warehouse conditions and often broke down, requiring forklift drivers to manually scan pallets—a step that added time to the process. On top of that, replacing both the cables and the scanners was expensive—costing more than $1,800 for a cable and upwards of $3,500 for a scanner, Toon Meirink, Zeelandia’s maintenance engineer, electrical and instrumentation, said in a 2024 case study about the project.
“What we had before wasn’t sustainable,” Meirink said.
The new solution combines Zebra’s FS40 rugged cordless scanners with wireless receivers from Bout Solutions and Zebra’s Aurora software. Because the scanners are easier to install than their predecessors and hold up to the rigors of the environment, the facility is experiencing less downtime and more consistent output.
But the real gains are financial.
“We will save at least 20,000 euros [nearly $21,000] on an annual basis with this application,” Meirink said.
Zeelandia can then pass those savings along to customers.
“Zebra’s solutions provide cost savings to achieve our mission,” Meirink explained. “If we can operate more cost-effectively, we can pass on the benefits to the customer by offering lower [prices]. Cost savings are obviously based on a lot of factors [such as labor] and material costs, but across the whole operation, [this technology] has definitely contributed to that goal.”
