Quick answer: A useful coding-cost comparison is built from your own message, material, labour steps and quality checks—not from printer price alone. For factories in Malaysia and Singapore, a short measurement exercise can make a proposal easier to compare and defend.

Why a coding-cost worksheet matters

When a factory considers direct inkjet coding, labels, stamps or another process, the discussion often begins with the equipment price. That number is real, but it is only one part of the workflow. The cost of a date code, batch number or QR code can also include the consumable used, operator handling, template changes, rejected packs, line interruptions and the work required to keep records accurate.

A simple worksheet does not promise that one technology will always be cheaper. It helps a production manager compare like with like and identify the questions that need a print trial before a decision is made.

Start with the exact code you need to print

Record the content exactly as it will appear on the pack or outer case: the number of text lines, character height, logo or code type, and whether the content changes by batch, shift, customer or destination market. A larger message, a dense barcode or a variable database field should not be treated as the same job as one short date code.

Also record where the code is printed. Product packs, bottles, cartons and pallets may need different print positions, templates or handling. This is the baseline for a realistic comparison.

Check material and ink before calculating anything

Ink selection affects both print quality and the expected workflow. BENTSAI documentation distinguishes water-based inks for porous or semi-porous materials from solvent-based inks for semi-porous and non-porous materials. Paper, corrugated board and wood are different from coated film, plastic, metal, glass or aluminium foil.

Do not assume that two materials that look similar will behave in the same way. Ask for a sample print on the actual production substrate and assess adhesion, drying, readability and placement under the intended handling conditions. The result of this trial belongs in the cost worksheet because a code that requires rework is not a low-cost code.

Measure the current workflow for one representative period

Choose a normal production shift, batch or week. Avoid using an unusually busy day or an exceptional order as the only reference. Capture the following information:

• Number of units, packs or cases coded
• Number of different messages or template changes
• Consumables used, including labels where relevant
• Operator time for applying, printing, checking and changing messages
• Rejected, reworked or relabelled items
• Time spent on cleaning, adjustment, troubleshooting or waiting

Use actual records where they exist. If a value is unknown, label it as an estimate instead of presenting it as a fact. This distinction keeps the calculation useful when management reviews it later.

Separate recurring costs from one-time implementation work

Recurring costs may include ink or labels, routine checks, operator time and replacement parts. One-time work may include installation, mounting, a sensor or encoder where required, template setup, staff training and a print trial. Mixing these categories can make a one-time purchase appear larger or smaller than its real impact over time.

For an inline workflow, include the practical requirements around product movement and triggering. For a handheld workflow, include alignment, physical handling and the frequency of message changes. The objective is not to favour a handheld or inline system; it is to describe the work that the factory will actually perform.

Use scenarios instead of a single “savings” claim

Create at least three scenarios: a normal run, a short run with frequent message changes, and a larger run with the same message. Compare the same code, substrate and output quantity in every scenario. This approach is more credible than claiming a universal saving percentage.

A useful review question is: “What would need to be true for this option to work as expected?” For example, the substrate must accept the chosen ink, the code must remain readable after handling, and operators must be able to follow the selected process. These conditions are as important as the cost line.

Where BENTSAI TIJ systems fit into the evaluation

BENTSAI offers handheld and inline thermal inkjet configurations. The appropriate model, cartridge and ink depend on the required print height, code content, substrate and workflow. A supplier discussion should confirm the proposed configuration and arrange a suitable application test before purchase.

PTS Technology can help Malaysian customers review these inputs and select a BENTSAI coding solution for the intended application. Singapore-based companies should confirm service scope, product availability and commercial terms before planning implementation.

A practical worksheet to take to a supplier discussion

Worksheet item	What to record
Code	Text, date, batch, barcode or QR content; print height and changes
Substrate	Actual material, finish and colour; sample-test result
Output	Units or cases per shift, batch and month
Current process	Consumables, labour steps, checks and rework
Proposed process	Equipment configuration, consumables, training and integration needs
Decision conditions	Readability, adhesion, workflow fit and support requirements

FAQs

Does direct coding always cost less than labels?

No. The outcome depends on the message, material, production volume, labour steps and quality requirements. Compare the actual workflow.

Should printer price be the only number in the comparison?

No. Include consumables, handling, template changes, rework, implementation work and support requirements.

Why is a substrate print trial important?

It helps confirm whether the selected ink and print setup are suitable for the material and intended handling conditions.

Can the same cost worksheet be used for handheld and inline printing?

Yes. Use the same headings, then record the different handling and integration requirements for each workflow.

What should be confirmed before ordering?

Confirm the model, ink, substrate test, expected code content, availability, training, support scope and warranty terms.

Next step: Bring a sample of the intended packaging, the required code artwork and a typical production quantity to a PTS Technology discussion. This makes the evaluation specific to your operation.