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Track & Trace is a critical system that enables end-to-end monitoring of individual products throughout their lifecycle, from item level to pallet level. Each product receives a unique identifier (UID) that is digitally recorded at every stage of production, packaging, storage, and distribution. This allows factories to instantly retrieve complete information about source materials, quality parameters, test results, production line, responsible operator, and timestamp for every individual unit. Modern traceability systems collect and analyze data in real time, delivering full visibility and compliance with strict industrial regulations.
Aggregation is one of the most critical elements of modern traceability. It creates a digital hierarchy where unique identifiers (UIDs) of individual products are linked to the identifier of the larger package containing them, forming a parent-child relationship. Standard hierarchy: Pack (from the manufacturing machine) -> Carton (from the packing machine) -> Case (case packer) -> Pallet (palletizer). With this digital tree, scanning only the pallet logistics barcode provides instant visibility of all contained individual packs. Any association error (aggregation mismatch) should trigger immediate line stop and product rejection. Without accurate aggregation, a traceability system cannot operate reliably.
Serialization means assigning a fully unique identifier to each individual product, enabling independent unit-level traceability. A UID (Unique Identifier) typically includes manufacturer ID, GTIN/SKU, unique serial number, aggregation reference, and checksum or cryptographic signature for security. GS1 SGTIN (for serialized products) and GS1 SSCC (for logistics units) are widely used standards. Batch tracking groups products made in the same period under a shared lot identifier based on production date and lot number. Both approaches can run together: serialization provides maximum granularity for targeted recalls and anti-counterfeit control, while lot tracking supports efficient management of consumed materials, equipment, and quality parameters at batch level.
Camera-based verification systems are essential for validating the quality of applied product codes. After a code is printed via laser or inkjet, high-resolution industrial cameras on the production line scan each code in real time, checking readability, contrast, dimensions, and data correctness. If the camera cannot read the code (No Read), the product is immediately flagged for rejection and automatically removed from the line. This guarantees that only products with fully readable codes continue to distribution, preventing downstream supply-chain failures. Modern camera systems can process over 2,000 products per minute and detect defects invisible to the human eye, including subtle contrast variations and partial Data Matrix damage.
There are three main coding technologies in Track & Trace systems. Laser coding is preferred for high-speed lines (over 2,000 products/minute), offering permanent marking with no consumable costs, though contrast can be challenging on some surfaces. Inkjet coding is mainly used at logistics levels (cases and pallets) for larger codes with excellent contrast, but it requires maintenance to avoid nozzle clogging and is sensitive to environmental conditions. Direct 2D Data Matrix marking is the industry standard for serialization because it stores large data volumes in small space and remains readable even when partially damaged. Codes are validated immediately after application by verification cameras to ensure lifetime readability. Final technology choice depends on line speed, packaging material, and durability requirements.
Traceability architecture requires tight integration with corporate IT infrastructure. The standard flow starts with a UID Generator creating unique identifiers and sending them to printers for physical marking. Industrial cameras then verify coding quality. A central Aggregation Server manages all hierarchical links between products and packaging. Data is transmitted through middleware layers using industrial protocols such as OPC-UA (for equipment communication) and TMC to MES/MII systems (Manufacturing Execution Systems) for real-time production monitoring. Finally, data is synchronized with ERP platforms (SAP, Oracle, Microsoft Dynamics) through REST APIs, SOAP web services, or custom connectors, enabling bidirectional exchange of production order, inventory, quality, and shipping data. This end-to-end integration eliminates manual data entry and provides organization-wide visibility.
Compliance with international regulations is fundamental in Track & Trace systems. In tobacco, highly strict regulations such as TTT (Track and Trace for Tobacco) and EU TPD (Tobacco Products Directive) require full traceability from factory to point of sale. GS1 standards provide the technical backbone: SGTIN (Serialized Global Trade Item Number) for individual products and SSCC (Serial Shipping Container Code) for logistics units. Our systems automatically generate GS1-compliant identifiers, including checksums and cryptographic signatures to prevent counterfeiting. For ISO 9001, we fully document processes for audits. For IATF 16949 (automotive), we ensure complete traceability of critical components. For ISO 22000/HACCP (food safety), we monitor critical parameters in real time. All data is archived according to legal retention requirements, and audit reports are generated automatically, reducing preparation time by more than 70%.
Full Track & Trace implementation duration depends on production-line complexity and required integration depth. A typical project takes 4-8 months and includes detailed process analysis and flow mapping, serialization/aggregation architecture design, hardware installation (laser/inkjet printers, verification cameras, reject systems), UID Generator and Aggregation server setup, OPC-UA integrations with equipment, MES/ERP connectivity configuration, extensive real-environment testing of all aggregation scenarios, complete training for production and IT teams, and post-go-live optimization support. Large projects with multiple lines or complex compliance requirements may require 10-14 months. We use a modular rollout approach that enables progressive go-live so selected lines can become operational earlier while minimizing impact on ongoing production.
Our complete range of services and products for traceability
In traceability processes, single product tracking ensures that each product has a unique number and is tracked through this unique number in all steps of the process.
Solution detailIn traceability processes, batch/lot tracking is preferred in processes where it is difficult to track products individually depending on the process.
Solution detailSiskon's P2L solutions provide visual guidance to operators regarding the next part and process in industrial production and assembly operations where manual labor is used.
Solution detailReal-Time Location Systems (RTLS) are used to automatically identify and track the locations of objects or people in real time.
Solution detailA Warehouse Management System, in a general sense, is a process that allows organizations to control and manage the entry and exit of goods or materials into and out of the warehouse.
Solution detailWe offer the necessary combination applications and solutions to ensure data transfer between independent applications, in short, to enable systems to talk to each other.
Solution detailReal implementation examples across industries
During the shipping process, a barcode-gate system installed at the exit ramp automatically reads all pallet labels.
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To ensure traceability for each product, a laser marking machine was developed for Phinia to support marking and identification processes.
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The Product | Carton | Pallet traceability application was successfully implemented on production lines at Duru Bulgur's Karaman factory.
DetailsOur trusted solution partners are leaders in their domains with proven global success.
Global leader in industrial sensing and automation technologies.
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Accessible automation, human robot collaboration, and pioneering innovation are the core messages of our identity.
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Product intelligence, supply chain integrity, and brand protection are the core messages of our identity.
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