Why Laser Marking is a Smart Investment: Benefits and ROI Explained

Michael Strzyz
Director Global Product Innovation, Videojet

November 12, 2025

Laser marking, Laser marking benefits, Laser marking ROI

Introduction

In today’s manufacturing environment, companies are under constant pressure to reduce costs, maximize operational efficiency, and comply with increasingly strict regulatory and sustainability requirements. As a result, many manufacturers are evaluating the advantages of laser marking as a long-term coding solution.

This article explores the key laser marking advantages, how to approach laser marking ROI calculations, what factors impact your laser marking return on investment, and why more manufacturers are choosing laser technology to maximize product marking ROI across their production lines.

How Laser Marking Technology Works

Laser marking in brief

Laser marking uses concentrated beams of light to permanently alter a surface without the need for ink, solvents, or ribbons. This makes it fundamentally different from ink-based coding methods like continuous inkjet (CIJ) and thermal transfer overprinting (TTO), which rely on consumables to create visible codes.

“CIJ and TTO apply ink to generate contrast. Lasers shoot photons at the substrate, and it only works if the material absorbs them. If not, it’s like shining light through a window. Nothing happens.”

— Michael Strzyz, Director Global Product Innovation, Videojet

Laser codes only form when the substrate absorbs the laser’s energy. If the surface reflects or transmits the beam instead, no mark will appear. This means laser marking is an absorptive process and highlights the importance of substrate compatibility and proper laser selection to achieve reliable and consistent results.

Choosing the right laser – A quick overview

Different materials absorb different wavelengths of laser light. That’s why choosing the right laser type for your application is essential. Here’s a high-level view of the main options:

Laser Type	Best For	Strengths
CO₂	Paper, PET bottles, cardboard, glass	Fast, cost-effective for organic materials
Fiber	Metals, hard plastics, electronics	High-precision, ideal for industrial applications
UV	Films, HDPE, vials, flexible packaging	Cold marking, minimal heat, suitable for delicate materials

“The innovation in our UV lasers is not just speed or versatility, but a complete performance package: SmartFocus™, safety integration, and adaptability to different materials.”

— Michael Strzyz, Director Global Product Innovation, Videojet

Want to explore the differences in more depth? Our Comprehensive Guide to Choosing a Laser Marking System dives deeper into absorption behavior, wavelength selection, marking methods, and industry use cases.

Key Laser Marking Benefits and Advantages

Laser marking offers a range of advantages that position it as a preferred solution over other coding technologies. Below are the core laser marking benefits that drive operational efficiency, cost savings, and sustainability—key factors in maximizing laser marking ROI.

No consumables = Lower operating costs

Laser marking systems do not require ink, solvents, or ribbons. This significantly reduces recurring costs and eliminates the need for consumables inventory management, directly impacting the laser marking return on investment and maximizing ROI in high-throughput production environments.

“One of the biggest differences we see is the disappearance of the constant consumables supply chain. That alone saves time, cost, and stress for production teams.”

— Max Owen, Product Manager – Lasers, Videojet

Low maintenance = More uptime

With few moving parts and a no fluid system, lasers need minimal intervention. Maintenance is generally limited to periodic lens cleaning or filter replacement, maximizing uptime and minimizing costly downtime.

“Lasers are incredibly reliable; you turn them on and they go.”

— Sascha Ammesdoerfer, Global Product Manager – Laser, Videojet

Permanent and high-quality codes

Laser marking produces durable, high-contrast codes that are resistant to heat, chemicals, abrasion, and fading. This is especially critical in industries like food, pharma, and automotive, where traceability and compliance are essential.

The high quality and permanence of these marks are achieved through various interactions with the material, not solely through burning.

“One of the biggest misconceptions is that lasers always mark by burning. That’s not true. There are also chemical color changes happening in certain interactions, so the mark is created in different ways than just by heat.”

— Max Owen, Product Manager – Lasers, Videojet

High speed and precision

Some laser marking systems can reach speeds up to 2,000 characters per second. For example, beverage lines can mark up to 100,000 cans per hour with consistent code clarity—demonstrating the clear laser marking advantages over traditional methods. The newest Videojet UV lasers now offer even higher speeds and efficiency, even on complex substrates.

Sustainability

Laser marking is a future-proof, more eco-conscious solution:

No ink means no packaging waste, spills, or chemical emissions during production.
No hazardous waste from cartridges or ribbons that need disposal.
Fewer shipments and supplies reduce transport emissions and environmental impact.
Significantly reduced VOCs (airborne pollutants found in inks and solvents) due to effective fume extraction systems that capture most smoke and debris produced.
Modern laser systems are energy-efficient and designed for long operational life.

“Laser marking aligns perfectly with our sustainability targets: no consumables, no waste, and minimal energy use.”

— Max Owen, Product Manager – Lasers, Videojet

Note: While laser systems use fume extraction filters that require responsible disposal, the overall environmental impact remains significantly lower than ink-based alternatives. The absence of solvent-based fluids means less operator exposure, no evaporated chemicals in the production environment, and no hazardous waste from used cartridges or containers.

Maximizing ROI with Laser Marking Using ROI Calculation

Laser marking systems often require a higher initial investment, but the long-term savings are substantial. When developing an ROI calculation for a laser marking system, it’s crucial to look beyond just the purchase price. A comprehensive evaluation should consider the full range of cost eliminations and significant operational laser marking benefits when compared to traditional coding methods. This approach aims to provide a true understanding of your laser’s return on investment.

Typical cost eliminations

Laser marking systems help reduce or eliminate several recurring operational expenses, making them a cost-effective choice with a strong return on investment. These savings are primarily the result of a more efficient, low-maintenance design that minimizes production interruptions and ongoing costs.

No consumables
Laser coders operate without inks, solvents, or ribbons. This removes the need for refills, storage, and purchasing — reducing both direct and indirect costs.
Minimal maintenance
Routine upkeep is typically limited to occasional lens cleaning, avoiding the labor and downtime linked to frequent maintenance or part replacement.
Higher uptime
With fewer moving parts and no consumables to manage, laser systems are less prone to interruptions, enabling more consistent production flow.
Long service life
With a typical lifespan of seven years or more, industrial laser coders deliver enduring value with a lower total cost of ownership over time.

As our industry expert points out, it’s not just about consumables — the true ROI lies in optimizing line efficiency:

“Some customers only calculate the ribbon, inks and solvents cost, but in high-volume plants, it’s about overall equipment efficiency. Less intervention means fewer operators—and that changes the economics.”

— Michael Strzyz, Director Global Product Innovation, Videojet

Calculating laser marking ROI: Maximize your savings

Every production environment has unique demands. To provide the most accurate and relevant insights for maximizing your laser marking ROI, our specialists collaborate closely with you. We use a professional laser marking ROI calculator to analyze your specific production process, volumes, and requirements. This detailed approach ensures a tailored ROI calculation that factors in critical elements like production throughput, shift schedules (1, 2, or 3 shifts/day), substrate transparency, and current downtime challenges.

This personalized consultation offers several key advantages:

Clear expectations: Gain a precise understanding of the short-term and long-term savings you can expect to achieve.
Transparent advice: Receive insights specifically tailored to your situation, not just a generic calculation.
Direct expert contact: Get immediate answers to your questions and direct recommendations for the optimal solution.

“At high-speed beverage lines—80,000+ bottles per hour—the laser ROI drops below three years easily. In confectionery, where product changes happen daily, laser can dramatically improve efficiency.”

— Michael Strzyz, Director Global Product Innovation, Videojet

For a precise assessment, connect with our experts for a personalized ROI calculation.

Get Your Personalized Laser ROI Calculation: (888) 960-1272

Where Laser Marking Adds the Most Value

Industries with strong ROI from laser

Food & bBeverage: Permanent best-before dates on bottles/cans = fewer recalls, no ink smudges. Crucial for maintaining product integrity and traceability.
Pharmaceuticals: Serialized codes that withstand sterilization, essential for compliance and patient safety. Lasers offer a high degree of code integrity.
Electronics: Precision marking on tiny components with high contrast.
Cosmetics & luxury goods: Subtle, elegant codes that protect brand image andcan deter counterfeiting.

“In pharma and beverage, we often see lasers adopted not just for cost, but because failure isn’t an option. The code has to stay readable, regardless of heat, moisture, or handling.”

— Michael Strzyz, Laser Technology Expert, Videojet

Laser Marking Integration Made Easy

Videojet laser marking systems are engineered for straightforward, plug-and-play integration. With features like SmartFocus™ (automated focus adjustment) and beam turning units for 360° flexibility, integrating laser marking into your line is simple—even in tight spaces. Laser heads can be easily mounted, and intuitive user interfaces make switching between products seamless. These laser marking advantages help minimize installation time and disruption.

Mechanical fit matters

Integrating a laser marking system into an existing production line requires careful consideration of physical space. Laser systems demand specific clearances for the laser head and beam delivery, which can be challenging in tight, upstream machinery and may even necessitate significant line redesign. However, their installation becomes notably simpler on more spacious downstream conveyor lines, allowing for standard mounting and easier alignment. Videojet actively addresses these challenges by developing increasingly compact laser models and versatile beam turning units, designed to simplify physical integration and help ensure optimal performance, even in confined industrial settings.

Safety first

At Videojet, safety is intrinsically built into our laser marking systems. They are engineered to meet stringent Class 1 laser safety standards, effectively transforming inherently powerful Class IV laser sources into safe operational units. This is achieved through integrated features such as comprehensive beam shielding, safety interlocks, and efficient fume extraction, helping ensure both operator protection and full compliance with international safety regulations from the design phase onwards.

Conclusion & Next Steps

Laser marking is more than just a marking method—it’s a strategic investment that delivers long-term value. The advantages of laser marking go far beyond eliminating consumables. By reducing maintenance, improving code quality and compliance, and supporting sustainability targets, laser marking helps companies not only cut costs but also build more resilient, future-proof operations.

If you want to understand the potential laser marking return on investment for your business, we encourage you to contact our experts for a personalized analysis using a dedicated laser marking ROI calculator, tailored to your production data and goals. As part of this consultation, we can also provide sample markings, demonstrate system capabilities, and recommend the best-fit configuration. It’s the most effective way to maximize ROI and implement a solution that delivers long-term value, safety, and performance for your operation.