Replacing barcode scanners in the warehouse

Is the hardware in your distribution center or warehouse outdated, are repair costs increasing, or does the operating system no longer support your latest software? Reverse IT is the specialist in replacing barcode scanners and PDAs in warehouses and distribution centers. We not only supply the hardware (such as Honeywell and Zebra), but also handle the entire process: from integration with your WMS/ERP system to on-site hardware installation and user training for warehouse management.

Request advice

The hidden costs of outdated warehouse scanners

Many logistics organizations postpone replacing barcode scanners for as long as possible. "They still work, don’t they?" is a commonly heard remark. However, in practice, continuing to use outdated hardware leads to significant hidden costs:

Loss of productivity due to slow batteries: Batteries that run out after just 3 hours of scanning cause constant trips to charging stations and interruptions in the order-picking process.
High ad-hoc repair costs: Outside the warranty period, costs for repairing touchscreens, scan engines, and connectors quickly escalate into poorly timed investments.
Frustration and errors on the shop floor: Mis-scans due to worn scanner windows lead to manual entry, drastically increasing the risk of incorrect deliveries.

"Most warehouses only replace scanners when failure becomes a problem. In practice, we see that organizations should have started their replacement process 12 to 18 months earlier to avoid peak loads and unexpected repair costs." - Arjan Zuidema, Technology Manager at Reverse IT.

By choosing a planned replacement in time, you transform an unpredictable cost item into a manageable, strategic investment that pays for itself in operational speed.

Why replace barcode scanners via Reverse IT?

Where traditional Auto-ID suppliers stop once the hardware has been delivered in boxes, Reverse IT’s service goes further. We believe in Reverse Thinking: we first look at the desired outcome and then design the hardware solution around it.

When you choose a transition project with Reverse IT, you benefit from unique advantages that the competition does not offer:

Mobile Device Management (MDM): After implementation, you maintain continuous control over your fleet. We configure the devices so that updates, security, and support are handled remotely.
Reduced device loss with MDC (Waizu): By combining the replacement of your equipment with our Waizu asset tracking software, you always know where every scanner is. This prevents expensive new devices from getting lost in the warehouse, allowing organizations to save up to 41% on total hardware costs.
Fully brand-independent: Whether your preference is the latest rugged handheld terminals from Zebra, Honeywell, or Datalogic, we advise on the hardware that truly fits your specific warehouse environment.

From onboarding to support

At Reverse IT, we believe in a personal, forward-looking approach in which technology serves business processes. We combine in-depth knowledge of mobile IT solutions with a pragmatic working method: from consulting and delivery to implementation, management, and support. To minimize downtime and ensure maximum control, we follow a fixed transition process consisting of 8 clear phases:

Inventory and analysis: We fully map your current hardware fleet, warehouse environment, and the specific requirements of your logistics process.
Test phase: We provide test devices (Proof of Concept) so that your employees can test the barcode scanners in practice within your own WMS beforehand.
Project planning: A tight, realistic schedule is created to ensure a smooth transition to the new scanners without any logistical downtime.
Acceptance phase: We align the final configurations, software integrations (ERP/WMS), and Mobile Device Management (MDM) settings with you for approval.
Implementation plan: The final rollout playbook is prepared, including the pre-configuration (staging) of all devices in our service center.
Roll-out: The new, plug-and-play configured barcode scanners and PDAs are physically delivered and prepared for use.
Go-live: The live deployment on the shop floor. We guide your team on site, test connections, and provide user training for immediate adoption.
Monitoring and evaluation: Even after go-live, we stay close. Through MDM we monitor performance, provide remote management, and offer support. Our service managers and support staff are ready to assist you immediately if needed.

By working closely with both our customers and leading technology suppliers, we deliver tailor-made solutions that increase efficiency, reduce costs, and contribute to a more sustainable IT strategy. This is how we guide your organization, from consulting to management, with maximum control and minimal worries.

The migration from Windows CE / Mobile to Android Enterprise

Are your current warehouse scanners still running the outdated Windows Mobile or Windows CE? Microsoft has long since stopped supporting these operating systems. This creates serious security risks and makes it impossible to connect with modern cloud software.

Reverse IT specializes in this legacy-to-Android migration. We safely guide your organization through this transition by:

Converting existing 'green screens' (telnet) into a modern, graphical, and intuitive Android touch interface.
Securing devices using Android Enterprise Recommended (AER) standards.
Helping employees quickly adapt to the new system, which reduces onboarding time for new (temporary) staff by 60%.

Useful checklist: When should you replace your barcode scanners?

Unsure whether you should take action now? Go through these 5 questions. If you can answer two or more with ‘yes’, then starting a replacement process is financially and operationally worthwhile:

Do the scanners regularly fail due to Wi-Fi dropouts because the internal Wi-Fi cards are outdated?
Have more than 3 devices been permanently decommissioned or irreparably damaged in the past year?
Do employees have to swap scanners halfway through their shift because battery capacity is too low?
Is the hardware still running on Windows CE or an Android version that no longer receives security updates?
Do order pickers experience delays because the barcode scanner struggles to read damaged or reflective labels (foil)?

Timely replacement of outdated hardware prevents costly ad-hoc repairs and frustration on the shop floor. Would you like to know how we can smoothly and cost-effectively set up the complete replacement process from onboarding to support for your organization?

Get in touch

References

“De support van Reverse IT is betrouwbaar en snel, waarbij vragen direct worden opgepakt en opgelost”

Anthony van Zon, Project Manager

≥95% binnen SLA opgelost

IT Support

“Met Reverse IT hebben we één stabiele IT-omgeving met meer controle en zekerheid”

Moshe van Ooijen, Directie

“Reverse-IT is een betrouwbare IT-partner die ons ondersteunt bij het beheer van warehouse devices en actief meedenkt over de optimalisatie van scanning en printoplossingen”

Alex van der Steen, Applicatiebeheerder

“Met Reverse IT aan onze zijde weten wij dat we altijd rekenen kunnen op snelle, deskundige ondersteuning – zowel technisch als met advies”

Jeroen Reijngoud, Head of Technology

Close-up van de robuuste Honeywell CT47 PDA die wordt gebruikt voor orderpicking in een magazijn

“De tijdwinst en verbeterde controle met MDM wegen ruimschoots op tegen de investering; we werken nu sneller en efficiënter”

Frank Voots, IT Manager

66% snellere onboarding

MDM-oplossing

“Reverse IT zorgt voor schaalbaar en betrouwbaar beheer van onze mobiele logistieke apparaten”

Bob Mulders, Head of IT infrastructure, Network and security

1800+ devices

In centraal devicebeheer

“De Zebra TC22 in combinatie met de MDM-service helpt ons om winkels sneller en efficiënter te ondersteunen”

Michel, applicatiebeheerder

Snellere en efficiëntere winkelprocessen

Hogere productiviteit

“We helped Batenburg with the consulting and implementation of Android hardware for an efficient transition within the organization.”

Ruben Swama, Reverse IT

“Consulting, implementation, and remote management of Android hardware ensure seamless integration and optimization.”

Stefan Manning, Reverse IT

“We offer consulting and implementation of Android hardware and ensure the continuity of end-of-life hardware.”

Stefan Manning, Reverse IT

FAQ barcode scanner replacement

What is a warehouse scanner?

A warehouse scanner is a rugged mobile computer with an integrated barcode reader used for order picking, inventory management, goods receiving, and shipping within warehouses and distribution centers.

When should you replace a barcode scanner?

A barcode scanner should generally be replaced when: The operating system is no longer supported; Repair costs exceed 30% of the replacement value; Batteries last less than one full shift; Wi-Fi or scanning performance noticeably declines.

What happens to our old barcode scanners?

Reverse IT offers attractive buy-back and trade-in options for your old hardware. We ensure certified data wiping so that no business data remains, and we guarantee environmentally friendly recycling or repurposing of old devices in accordance with applicable regulations.

Can you test the new scanners in our warehouse beforehand?

Yes, we believe in the power of a Proof of Concept (PoC). As indicated in our Test Phase (Step 2), we provide test devices so your employees can thoroughly test the scanners in your own environment first.

Do you also support the transition from Windows to Android?

Absolutely. Many older warehouse scanners still run outdated Windows operating systems (such as Windows CE). We specialize in migrating to Android Enterprise, including converting or optimizing the user interface for your employees during the onboarding process.

Do you also supply related items such as label printers?

Yes. In addition to supplying and managing hardware, we can also provide the necessary supplies (such as thermal labels, shipping labels, and print ribbons) that are perfectly matched to your new scanning and printing equipment.

Inventory and analysis: We fully map your current hardware fleet, warehouse environment, and the specific requirements of your logistics process.
Test phase: We provide test devices (Proof of Concept) so that your employees can test the barcode scanners in practice within your own WMS beforehand.
Project planning: A tight, realistic schedule is created to ensure a smooth transition to the new scanners without any logistical downtime.
Acceptance phase: We align the final configurations, software integrations (ERP/WMS), and Mobile Device Management (MDM) settings with you for approval.
Implementation plan: The final rollout playbook is prepared, including the pre-configuration (staging) of all devices in our service center.
Roll-out: The new, plug-and-play configured barcode scanners and PDAs are physically delivered and prepared for use.
Go-live: The live deployment on the shop floor. We guide your team on site, test connections, and provide user training for immediate adoption.
Monitoring and evaluation: Even after go-live, we stay close. Through MDM we monitor performance, provide remote management, and offer support. Our service managers and support staff are ready to assist you immediately if needed.