A growing number of consumer packaged goods (CPG) and industrial manufacturers are recognizing the distinct advantages of laser marking technology. These versatile and reliable systems deliver permanence, flexibility, and speed, capable of applying high-quality marks across a wide range of substrates. This enables businesses to meet increasing demands around laser marking safety, traceability, sustainability, and compliance.
Yet, despite these benefits, several myths about laser marking technology persist. Is it true that laser marking is unsafe? Is it too expensive? Or are laser systems truly hard to integrate and operate? Let’s separate fact from fiction and reveal the truth behind these and other common misconceptions in the market today, backed by insights from Videojet laser experts.
Myth 1: “Laser Marking is Unsafe.”
Reality: Laser marking machines built to meet Class 1 laser safety standards
By nature, the laser sources used in industrial marking systems are classified as Class 4 lasers. This means they emit high-power beams that can pose significant hazards to eyes and skin, and even present a fire risk, if not properly contained. However, when these powerful laser sources are integrated and operated properly within a complete system, they are not only safe, but often safer than alternative technologies.
Videojet laser marking systems are meticulously built to Class 1 laser safety standards. This transformation from a Class IV laser source to a Class 1 safe system is achieved through the incorporation of robust engineering controls like full beam shielding, interlocks, and fume extraction. This rigorous approach helps ensure the safety of personnel and the operational environment, making laser marking safety a top priority in design and implementation.
“We certify each system upon installation. If nothing changes, the setup is safe for life.”
Key safety measures
Beam shielding: Prevents direct and reflected radiation exposure, essential for both laser marking safety and operator protection. Sascha Ammesdoerfer, Product Expert Laser Technology at Videojet, highlights: “A common mistake is shielding with gaps. Beam shielding must be completely light-tight to be effective.”
Interlocks: These safety mechanisms ensure the system automatically stops if safety components are misaligned or opened, providing an immediate safeguard against accidental exposure.
Fume extraction systems: Remove harmful particles, dust, and maintain air quality. This is a crucial part of industrial laser safety, especially as laser marking can generate sub-micron particles, which are a health hazard. Effective extraction prevents these particles from entering the breathing zone of operators, helping ensure a healthy working environment.
Proper mounting and vibration control: Avoids distorted codes and reduces operator risk by maintaining the stability of the laser system, contributing to overall laser marking safety.
Compliance requirements
Systems must meet IEC 60825-1 for laser safety and be CE certified in Europe, indicating conformity with health, safety, and environmental protection standards.
A laser risk assessment (RI&E) is often required during installation to ensure all safety measures are in place and potential hazards are identified and mitigated. This critical step helps ensure a safe operational environment.
Operator training is strongly recommended for correct and safe use, empowering staff to operate the equipment responsibly and understand safety protocols. This is a foundational element of effective industrial laser safety.
Summary
Industrial laser systems, though inherently powerful Class IV laser sources, are meticulously engineered and certified to meet Class 1 laser safety standards when integrated into a complete marking solution. This makes them a safe and reliable choice for industrial environments. These systems often set a higher benchmark for industrial laser safety, frequently surpassing the safety of traditional coding methods by minimizing risks associated with consumables and manual interventions, all supported by a thorough laser risk assessment.
Myth 2: “Laser Marking is too Expensive.”
Reality: Laser marking cost is lower over time
While laser marking systems often require a higher upfront investment—especially for fiber and UV lasers—in practice, the overall laser marking cost over the system’s lifespan is frequently lower than traditional technologies like continuous inkjet (CIJ) or thermal transfer overprinters (TTO). This is due to the elimination of ongoing consumable costs and significantly reduced maintenance, leading to a compelling Total Cost of Ownership (TCO).
“If you compare a CO₂ laser with a CIJ printer over five years, including consumables, maintenance, and downtime, the costs typically converge. However, laser wins in cleanliness, uptime, and reliability.”
Why laser marking is cost-effective
No consumables: No inks, solvents, or ribbons to refill or stock. While fume extraction filters do need occasional replacement, this technology still offers a substantially reduced waste solution compared to consumable-based technologies that generate hazardous waste.
Minimal maintenance & operator intervention: Maintaining laser marking systems is remarkably simple, often just requiring periodic lens cleaning. This significantly reduces downtime and simplifies operational efforts.
Longer lifespan: Industrial laser systems typically last seven years or more, providing a durable and long-term coding solution.
Higher uptime: No production interruptions for consumable changes or frequent maintenance, maximizing operational output and reducing costly downtime.
Typical payback period
The typical payback period for an industrial laser system ranges from three to seven years, depending on the application, shift patterns, and substrate. This often aligns with or is even shorter than the lifespan of the equipment, showcasing a strong return on investment in terms of laser marking cost.
“Customers know a fiber or UV laser costs more than CIJ, but theyʼre willing to invest for the efficiency and autonomy.”
More than just cost savings
Beyond direct savings on consumables and maintenance, laser marking often provides additional value:
Support for sustainability: No waste from inks or ribbons, contributing significantly to environmental goals and reducing a company’s carbon footprint.
Reliable coding: Permanent, tamper-proof marks improve traceability, brand protection, and compliance with regulatory standards.
Reduced operator burden: Higher safety and fewer manual interventions contribute to a better working environment and allow operators to focus on more value-added tasks.
Summary
While the initial laser marking cost may appear higher upfront, laser marking systems offer a lower total cost of ownership (TCO) over their lifespan. This is achieved through minimal maintenance requirements, the elimination of recurring consumable expenses, and the added long-term value they provide for enhanced traceability, sustainability initiatives, and improved operational efficiency.
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Myth 3: “Laser Systems are Hard to Integrate and Operate.”
Reality: With the right support, integration is seamless and operation is simple.
Modern industrial laser systems from Videojet are designed for easy integration and user-friendly operation, even in complex manufacturing environments. When bundled with full-service integration, Videojet provides turnkey solutions—including the laser source, beam shielding for Class 1 laser safety, fume extraction, mounting hardware, and automation connectivity. This comprehensive approach eliminates the risks of “box-selling,” where customers must manage safety and compliance, such as laser risk assessment, on their own. As Michael Strzyz, Director of Global Product Innovation at Videojet, emphasizes, it’s not just about “buying a laser,” but about “buying the expertise to get that laser to work well.” This helps ensure a smooth and secure integration process.
Ease-of-use innovations
SmartFocus™: Automatically adjusts the laser focal distance based on product height—even at high speeds. This feature significantly reduces setup time and helps ensure consistent mark quality on varying product sizes.
“The system adapts between products within milliseconds—even on lines running 80,000 units per hour. That’s a game-changer.”
Beam turning units: Allow flexible installation and save valuable space in tight production lines, enabling integration into existing layouts without extensive modifications.
Plug-and-play integration: Videojet modern systems are designed for straightforward setup, minimizing the complexity typically associated with new equipment installation.
Intuitive user interfaces: Simplify operation and automate job changeovers, reducing operator training time and potential for errors, enhancing overall laser marking safety by minimizing manual intervention.
Key integration considerations
Fixed, vibration-free mounting is essential for precise marking and consistent laser marking safety, ensuring the laser beam remains stable.
Beam shielding and fume extraction systems are mandatory to ensure compliance with industrial laser safety standards and maintain a safe working environment.
Integration is performed with full support from Videojet technical experts. For CE certification and validation, customers are typically advised to engage an independent third-party company to ensure the system meets all necessary European safety, health, and environmental protection requirements. This mitigates potential risks identified during a laser risk assessment.
“Unlike CIJ, lasers aren’t designed to be moved between lines. That’s a limitation, but also a safety benefit.”
Summary
Videojet laser systems are engineered for easy integration and operation, especially when supported by expert guidance and turnkey solutions, helping ensure robust industrial laser safety and efficiency. The emphasis on comprehensive support means manufacturers receive not just a product, but a fully integrated and optimized marking solution, and that all aspects of a laser risk assessment are covered.
Myth 4: “Lasers Require too Much Maintenance.”
Reality: Laser systems are low-touch, low-risk, and highly reliable.
Industrial laser systems are among the lowest-maintenance coding technologies available. While CIJ and TTO systems have their own strengths, they typically involve consumables like ink or ribbons and require regular upkeep. In contrast, laser marking systems operate without consumables and have minimal moving parts, helping reduce maintenance needs and limiting operator exposure to chemicals. This enhances both efficiency and laser marking safety.
Typical maintenance requirements
Lens cleaning: Simply wipe the focusing lens every 4–6 weeks, a task that usually takes about 30 seconds. This is the primary regular maintenance task, helping ensure consistent mark quality.
Fume extractor filter check: Occasionally inspect or replace filters, especially in dusty environments, to help ensure continuous effective fume removal and maintain air quality.
No consumables: No ink, ribbon, or solvents to manage, eliminating the logistical complexity and recurring costs associated with consumable-based printers.
“Cleaning the lens takes 30 seconds. That’s it.”
Summary
Videojet laser marking systems require minimal maintenance, with virtually no consumables and only occasional lens cleaning, making them a highly reliable and efficient choice for industrial coding. Their low-touch nature translates to fewer touchpoints, lower maintenance costs, fewer operator errors, and less unplanned downtime, which directly improves Overall Equipment Effectiveness (OEE). This approach also supports robust laser marking safety by minimizing manual interventions and reducing exposure to potential hazards, and positively impacts the overall laser marking cost for manufacturers.
Myth 5: “Lasers Can’t Mark Sensitive Materials.”
Reality: Different laser types cover nearly every substrate.
Industrial laser systems are highly versatile. With the correct laser type and wavelength, it’s possible to mark almost any material, even those considered sensitive or challenging. That’s why Videojet offers a full portfolio of CO₂, fiber, and UV laser systems — each engineered for specific substrates and applications. Michael Strzyz, Director of Global Product Innovation at Videojet, explains that laser technology is an “adsorptive technology,” meaning the marking effect depends on the material’s ability to absorb photons. If the material doesn’t absorb the photons, nothing happens, similar to light passing through a window. This fundamental principle guides material compatibility.
Etching, engraving, foaming, color change (e.g., clear plastics)
Best ROI for suitable materials, cost-effective
Fiber
Metals, Hard plastics
Oxidizing reaction on surface (creates black mark)
Durable marks on robust materials
UV
Flexible films, White bottle caps, Medical packaging, Heat-sensitive materials
Chemical color change with minimal thermal impact (“hyper localized sunburn”)
Preserves integrity of delicate materials
“We’re now using UV to mark substrates that couldn’t be coded by CO₂ or fiber before—like yogurt lids or dairy caps.”
Most CPG, pharma, and industrial applications can be covered by laser marking—provided the system is correctly matched to the substrate. This careful selection also supports laser marking safety and helps ensure high-quality, permanent codes without damaging sensitive materials. Max Owen, Product Manager for Laser Technology at Videojet, also clarifies that lasers mark in different ways than just burning; chemical color changes can also occur, broadening the range of applicable materials.
Limitations and considerations
Lasers rely on the contrast created by the material interaction; they don’t offer color variability. The mark is typically the result of a physical or chemical change within the substrate itself.
Laser marking is not ideal for high-resolution graphic printing, such as detailed address labels, as their strength lies in precise coding and serialization.
Industries benefiting from laser marking on sensitive materials
Pharmaceuticals: Serialized and 2D codes on delicate packaging where mark integrity and lack of material degradation are critical for regulatory compliance and patient safety.
Cosmetics: Anti-counterfeit marking on sensitive surfaces, maintaining product aesthetics and brand reputation.
Food & beverage: High-throughput lines and reduced contamination risk, especially for flexible films and caps.
“The substrate defines the laser. Think of CO₂, fiber, and UV like different screwdriver tips—each fits a specific job.”
Summary
With the right laser type and configuration, even sensitive and challenging materials can be marked safely and effectively, making laser marking a reliable choice across various industries. The key is understanding the material’s properties and matching it with the appropriate laser technology.
Conclusion & Next Steps
Laser marking technology has evolved into a safe, cost-effective, and highly versatile solution for today’s manufacturing challenges. By debunking common myths and focusing on facts, it’s clear that with the right integration and a thorough laser risk assessment, businesses can achieve optimal industrial laser safety and efficiency. Additionally, when you consider the total laser marking cost—including reduced maintenance and no consumables—lasers deliver unmatched value now and for the future, while adhering to the highest standards of Class 1 laser safety.
If you’re evaluating whether laser marking is right for your operation, we invite you to contact us for a consultation or demo. Our team can assess your specific requirements, provide sample marks, and recommend the best-fit system. With the right approach, you can unlock a solution that enhances safety, simplifies production, and delivers measurable results—fact, not fiction.
