The first automated system for machine-readable tracking was invented in 1969 by David J. Collins, an engineer at Sylvania. Originally designed for railroads using reflective color-coded labels, his KarTrak ACI system laid the groundwork for modern barcode scanning technology. The first retail barcode scanner, using black-and-white UPC codes, debuted in 1974.
But how did this breakthrough happen? Why did the world need a barcode scanner in the first place? And how did this 1969 invention evolve into the universal scanning systems we rely on today? Let’s dive into the full story.
The Problem Before 1969: Why Did We Need Barcode Scanners?
Before barcodes and scanners, tracking inventory was painfully slow and prone to errors. Large industries—railroads, supermarkets, and warehouses—depended on manual data entry, handwritten logs, and inefficient methods to track millions of moving parts.
Early barcode concepts existed—a circular 'bullseye' design was patented in 1952—but practical linear barcodes and scanners emerged in the 1970s. Without an automatic scanning device, barcodes were just symbols without purpose.
This was the challenge David J. Collins set out to solve.
The invention of the barcode scanner in 1969 was nothing short of revolutionary. Up until that point, barcodes existed, but there was no practical way to read them efficiently. That all changed when David J. Collins introduced KarTrak ACI (Automatic Car Identification), the world’s first industry-wide high-volume commercial barcode scanner.
But how did this invention originate? What was the key to its success? And why didn't it endure? Let's analyze it step by step.
David J. Collins & The Birth of Optical Barcode Scanning
By the late 1960s, technology had evolved enough to make automated scanning possible. Two key innovations made this breakthrough achievable:
- High-intensity light sources (lasers & photomultipliers) → Could detect and read data quickly.
- Computer advancements → Allowed automated data processing.
With these tools at his disposal, Collins, now working at Sylvania, led a team to develop the world’s first barcode scanner—a system that could track train cars as they moved.
How Did the First Barcode Scanner Work?
Unlike today’s black-and-white barcode strips, Collins' first barcode scanner used colored patterns on train cars. Here’s how it worked step by step:
- Color-Coded Stripes: Instead of black and white lines, KarTrak ACI used red, blue, and white reflective stripes, arranged in a specific pattern to encode information.
- High-Powered Light Source: KarTrak scanners used a high‑intensity quartz‑halogen (≈ 500 W) or xenon arc lamp to flood the label with light as a train passed.
- Photomultiplier Tube (PMT) Technology: The scanner used a photomultiplier tube to detect the reflected light from the colored bars. PMTs were highly sensitive, making it possible to capture data even when the train was moving fast.
-
Data Conversion & Storage: The reflected light turned into digital data, which was then:
- Printed onto magnetic tape for record-keeping.
- Sent directly to early computer systems for processing.
This fully automated system allowed trains to be tracked in real-time, without human intervention. It was a groundbreaking achievement, marking the first time that barcodes were scanned by a machine.
The Challenges & Why KarTrak Failed
Despite its technological breakthrough, KarTrak ACI was ultimately abandoned by 1978. Why? The answer lies in three key challenges:
1. Environmental & Durability Issues
Train cars travel through harsh conditions—rain, snow, dirt, and sun exposure. Over time, the color-coded stripes became dirty or faded, making them difficult to scan accurately. Unlike today’s black-and-white barcodes, which are more resilient, KarTrak’s colored patterns struggled under real-world conditions.
2. High Costs & Limited Computing Power
The 1960s and 70s were still the early days of computing. Processing barcode data required large, expensive computers, making it impractical for many companies to adopt. Maintaining the scanning equipment was costly, and businesses were reluctant to invest in an unproven system.
3. The Railroad Industry’s Financial Struggles
Just when KarTrak was gaining traction, the railroad industry faced a series of bankruptcies in the 1970s. With many rail companies shutting down, there was no money left to maintain or expand the system.
As a result, by 1978, KarTrak was officially abandoned.
Although KarTrak ACI failed commercially, its core technology became the foundation for the barcode scanners we use today.
- The concept of scanning barcodes with light detection → Later evolved into laser barcode scanners in the 1980s.
- Automated tracking of moving objects → Became the standard in retail, logistics, and inventory management.
- The idea of machine-readable codes for product identification → Led directly to the development of UPC codes (1973) and QR codes (1994).
Collins’ work proved that barcode scanning was possible, and within a decade, supermarkets and retail stores began adopting laser-based barcode scanners for products. By the 1980s, barcode scanning was widely adopted in the U.S. retail sector. Global standardization, however, coalesced in the 1990s with organizations like GS1 unifying formats.
From Failure to Revolution: How KarTrak Led to Modern Barcode Scanning
The failure of KarTrak didn’t stop barcode scanning. Instead, it pushed David J. Collins and other innovators to refine and adapt the technology for new industries, leading directly to the barcode revolution of the 1970s and beyond.
Moving from Color Stripes to Black-and-White Barcodes
One of KarTrak’s biggest issues was color degradation. Over time, dirt, fading, and harsh weather made it difficult to scan the red, blue, and white reflective bars.
To solve this, engineers shifted to black-and-white barcode patterns, which were:
- More durable (less affected by dirt or fading)
- Easier to print on different materials
- Compatible with early laser scanning technology
This shift laid the foundation for UPC barcodes, which would soon change the retail industry forever.
Laser Scanners: A Game-Changer for Barcode Reading
KarTrak relied on 500-watt incandescent light bulbs, which:
- Were inefficient and produced a lot of heat
- Required photomultiplier tubes to interpret the reflections
- Were limited in scanning angles
By the early 1970s, a breakthrough happened: laser technology became commercially viable.
- Lasers could scan barcodes from multiple angles.
- They provided stronger, more accurate illumination.
- They enabled smaller, more portable barcode scanners.
After leaving Sylvania, Collins founded Computer Identics, which by the early 1970s pioneered laser-based scanning systems. These became critical for warehouses and factories, marking a leap toward modern scanners.
It was a pioneering feat, marking the initial use of machine-scanned barcodes.
Standardizing the Barcode: The Birth of UPC (1973-1974)
The biggest problem with KarTrak was that it was limited to railroads. To make barcode scanning truly universal, the retail industry needed a single standard that all manufacturers and stores could use.
- In 1973, a team of experts—including IBM engineers like George Laurer—developed the Universal Product Code (UPC).
- Unlike KarTrak’s color stripes, UPC was a simple black-and-white barcode with vertical lines that stored product data.
- On June 26, 1974, a pack of Wrigley’s Juicy Fruit gum had the first UPC barcode scanned at a Marsh supermarket.
This moment marked the beginning of barcodes in retail, proving that barcode scanning was not just a failed railroad experiment—it was the future of global commerce.
Expansion Beyond Retail: Barcodes Take Over the World (1980s-2000s)
Once UPC codes became mainstream, barcode technology rapidly expanded into new industries:
- Warehouses & Logistics → Better tracking of shipments & inventory
- Healthcare → Patient safety, medication tracking, & hospital ID bracelets
- Libraries → Faster book checkouts & automated cataloging
- Airlines → Printed boarding passes with barcodes
By the 1990s, 2D barcodes like PDF417 (1991) and QR Codes (1994) were introduced, allowing even more data to be stored in barcodes.
So, even though KarTrak failed, Collins’ vision didn’t—it evolved into a technology that changed the world.
Today, barcode scanners are faster, smarter, and more accurate than ever—all thanks to the lessons learned from KarTrak’s first attempt in 1969. 🚀
Laser barcode scanners debuted industrially in 1969 and reached retail checkouts on 26 June 1974, replacing photomultiplier‑based readers more than a decade before the 1980s. Today, Tera’s latest barcode scanners use advanced 2D scanning technology, allowing businesses to quickly scan even the most complex barcodes—perfect for retail, warehouses, and healthcare.
The Future of Barcode Scanning: What’s Next?
Even though barcode scanners have evolved, the technology isn’t going away anytime soon.
- GS1’s Sunrise 2027 calls for checkout systems to read both 1D UPC/EAN and approved 2D barcodes, enabling—but not forcing—a gradual migration to 2D symbols.
- RFID & AI Scanners → RFID can track items without a direct scan, and AI improves recognition accuracy.
- Smrtphone Barcode Scanning → No hardware needed—just scan with your phone!
Barcode scanners have evolved significantly since Collins' 1969 invention, and they're improving constantly.
Conclusion: The Lasting Impact of the 1969 Barcode Scanner
David J. Collins invented the first barcode scanner in 1969 to solve a railroad tracking problem. His work became the foundation for modern retail scanning, logistics, and global commerce.
Next time you scan a product at checkout or see a QR code, remember—you’re using technology that started over 50 years ago with one man's vision.
From managing inventory to expediting checkout, barcode scanning tech keeps advancing. Tera’s scanners provide the precision, toughness, and speed you need for seamless operations. Want to enhance your barcode scanning? Discover Tera’s top-notch products now.
FAQs
What industries used barcode scanning after its invention in 1969?
→ After railroads, barcode scanners spread to retail, logistics, and healthcare, with supermarkets adopting them in the 1970s to speed up checkouts.
How did the advent of computers impact barcode scanners?
→ The rise of smaller, cheaper computers in the 70s and 80s made barcode scanners more accurate and efficient, leading to their widespread use, especially in retail.
Who invented the QR code?
→ Masahiro Hara at Toyota’s Denso Wave in 1994, originally for tracking auto parts.
