Datalogic 937401025 STS400-007 Tire Sorting & Traceability System: Real-World Application

The Datalogic 937401025 STS400-007 is a multi-head tire sorting and identification solution designed specifically for automated tire tracking and traceability. The product is configured with 7 reading heads and standard 0.30 mm (12 mil) resolution, providing a reading width of 1,085 mm for passenger and light-truck tire applications.

Unlike a conventional single barcode scanner, the STS400 is a complete, pre-assembled identification solution designed to capture tire barcodes from different positions as tires move through a production or sorting line. Datalogic developed the system to address the particular challenges of reading tire barcodes, including low-aspect-ratio codes whose quality can deteriorate during manufacturing.

1. Application in Automated Tire Sorting

One of the most important applications of the STS400-007 is automated tire sorting at the end of the manufacturing process.

After tires have completed manufacturing and inspection, they need to be identified and routed to the correct destination. Tires may be transported continuously by conveyors, making manual identification inefficient and prone to errors.

The STS400 can be installed over the sorting conveyor to automatically identify the barcode on each tire.

A typical process is:

Tire Production → Barcode Identification → STS400 Reading System → Sorting Control System → Automatic Routing → Storage / Shipping

The system can therefore connect barcode information with the physical tire and allow the production control system to determine where each tire should be sent.

Datalogic specifically identifies tire sorting and shipping as an important application for its industrial identification solutions.

2. Tire Tracking and Traceability

Traceability is particularly important in tire manufacturing because each tire may need to be tracked throughout multiple production and logistics stages.

The STS400 was developed specifically to address demanding Tire Tracking and Traceability requirements.

For example, a tire can be associated with information such as:

• Tire identification number
• Production batch
• Manufacturing date
• Product specification
• Quality inspection information
• Storage location
• Shipping destination

When the tire passes through the STS400 reading station, its barcode can be captured automatically and transferred to the plant’s control or information system.

This creates a digital link between the physical tire and its production or logistics data.

3. Handling Difficult Tire Barcodes

Reading barcodes printed or applied to tires is more difficult than reading conventional labels on flat products.

During tire manufacturing, processes such as vulcanization and surface treatments can reduce barcode contrast and affect the quality of low-aspect-ratio codes. Datalogic notes that these conditions can create no-read situations and increase manual handling if unsuitable identification technology is used.

The STS400 addresses this challenge using multiple image-based readers positioned around the tire reading area.

The 937401025 STS400-007 configuration provides:

• 7 reading heads
• 0.30 mm / 12 mil linear code resolution
• 1,085 mm reading width
• 250 mm depth of field
• 890–1,140 mm reading distance

These specifications allow the system to cover a relatively wide tire identification area.

4. Multi-Head Reading for Reliable Identification

The seven-head configuration is one of the key advantages of the STS400-007.

Instead of depending on a single reader positioned at one angle, the STS400 uses multiple reading heads to provide broader coverage around the tire.

This is particularly useful because tires are:

• Round
• Curved
• Variable in diameter
• Frequently positioned differently on conveyors
• Difficult to scan from a single fixed angle

The multi-head architecture improves the opportunity for a barcode to enter the field of view of at least one reader.

For automated tire production, this can help reduce no-read events and minimize the need for manual barcode verification.

5. Application in End-of-Line Production

A typical real-world application is at the end of a tire manufacturing line.

After a tire has completed production and quality inspection, it enters an automated conveyor system.

Step 1: Tire Enters the Reading Area

The finished tire moves toward the STS400 station on the conveyor.

Step 2: Multiple Readers Capture the Barcode

The seven reading heads monitor the defined reading area and capture the barcode from the tire.

Step 3: Barcode Data Is Decoded

The identification system processes the captured information and determines the tire’s identification data.

Step 4: Data Is Sent to the Production System

The decoded information can be associated with production, inventory, quality, or logistics data.

Step 5: Tire Is Automatically Sorted

The control system determines the appropriate destination and sends the tire to the corresponding sorting lane.

This process reduces manual identification and helps maintain continuous production flow.

6. Integration with Warehouse and Logistics Operations

The application of the STS400 does not have to stop at manufacturing.

After production, tires must often be stored, grouped, and prepared for shipment. Automated identification provides the data needed to track tires through these stages.

Datalogic notes that barcode technology plays an important role in inventory, storage, logistics, sorting and shipping.

For example:

Finished Tire → STS400 Identification → Warehouse Database → Storage Location → Order Matching → Shipping

This allows manufacturers and distribution centers to maintain better visibility of tire inventory.

7. Supporting Quality Control

The STS400 can also contribute to quality-control workflows.

A tire’s barcode can be associated with inspection information stored elsewhere in the manufacturing system.

For example:

When the barcode is automatically identified, the manufacturing system can retrieve the corresponding information and make routing decisions.

This helps reduce the possibility of sending the wrong tire to the wrong location.

8. Real-World Example: Automated Tire Distribution

Consider a tire manufacturer producing several different tire specifications on the same production line.

Without automated identification, operators may need to manually inspect tire labels and sort products into different destinations.

With an STS400 system installed at the end of the line:

1. Finished tires arrive continuously on the conveyor.

2. The STS400-007 captures the tire barcode.

3. The production system identifies the tire.

4. The system checks the corresponding production and logistics information.

5. The conveyor control system determines the correct sorting destination.

6. The tire is automatically routed to the appropriate storage or shipping area.

This approach can improve throughput while reducing manual handling.

9. Installation and Maintenance Advantages

Another important advantage of the STS400 platform is its integrated mechanical design.

Datalogic describes the STS400 as a self-contained, pre-assembled and calibrated solution. The company states that the system can be integrated into a tire sorting line quickly without requiring special tools or extensive training.

The system is also designed without moving parts, which helps reduce maintenance requirements. A green-spot indicator can provide local feedback about successful reading, while the reader replacement procedure is designed to simplify maintenance.

For a production facility operating continuously, these features can help reduce downtime during installation and servicing.

10. Why the 7-Head STS400-007 Configuration Matters

Datalogic offers different STS400 configurations depending on the required reading width and application.

For the standard-resolution passenger/light-truck tire range:

Therefore, 937401025 / STS400-007 is particularly useful when the application requires a 1,085 mm reading width while maintaining the standard 0.30 mm resolution.

Key Benefits in Tire Manufacturing

Improved Traceability

Every tire can be automatically associated with its identification data as it moves through production and logistics.

Reduced Manual Handling

Automated barcode identification reduces the need for operators to manually inspect and sort tires.

Wide Reading Coverage

Seven reading heads provide a 1,085 mm reading width for the specified standard-resolution configuration.

Reliable Identification

The multi-head architecture is designed to handle the difficult barcode-reading conditions found in tire manufacturing.

Faster Sorting

Automated identification allows sorting equipment to process tires continuously as they move along the conveyor.

Simplified Installation

The STS400 is supplied as a pre-assembled and calibrated solution, helping simplify integration into tire sorting systems.

Better Production Visibility

Barcode information can be connected with production, quality, warehouse, and shipping data to provide greater traceability.

Conclusion

The Datalogic 937401025 STS400-007 is more than a conventional barcode reader. It is a 7-head automated tire sorting and identification solution designed for demanding tire manufacturing and logistics applications.

With 0.30 mm standard resolution, 1,085 mm reading width, 250 mm depth of field and a 890–1,140 mm reading distance, the STS400-007 is designed to provide broad barcode coverage for passenger and light-truck tire applications.

In a real production environment, it can be used to automatically identify finished tires, connect barcode information with production and inventory data, support end-of-line sorting, and improve tire tracking from manufacturing through storage and shipping.

For tire manufacturers looking to reduce manual handling and improve traceability, sorting efficiency and production visibility, the Datalogic STS400-007 provides a purpose-built industrial identification solution