fixed QR code size and barcode send to printer

src/main/java/com/utopiaindustries/service/BarcodeService.java

@@ -1,11 +1,16 @@
 package com.utopiaindustries.service;
 
 import com.google.zxing.BarcodeFormat;
+import com.itextpdf.io.font.constants.StandardFonts;
+import com.itextpdf.io.image.ImageData;
 import com.itextpdf.kernel.colors.ColorConstants;
+import com.itextpdf.kernel.font.PdfFont;
+import com.itextpdf.kernel.font.PdfFontFactory;
 import com.itextpdf.kernel.pdf.PdfPage;
 import com.itextpdf.kernel.pdf.canvas.PdfCanvas;
 import com.itextpdf.layout.element.AreaBreak;
 import com.itextpdf.layout.element.Paragraph;
+import com.itextpdf.layout.property.AreaBreakType;
 import com.itextpdf.layout.property.TextAlignment;
 import com.utopiaindustries.dao.ctp.*;
 import com.utopiaindustries.model.ctp.*;
@@ -29,6 +34,7 @@ import com.itextpdf.layout.element.Image;
 import javax.imageio.ImageIO;
 import java.awt.image.BufferedImage;
 import java.io.ByteArrayOutputStream;
+import java.net.Socket;
 import java.nio.file.Path;
 import java.nio.file.FileSystems;
 
@@ -58,6 +64,18 @@ public class BarcodeService {
     @Value("${ctp.printer.port}")
     private int port;
 
+    @Value("${ctp.printer.bundleIpAdd}")
+    private String bundleIpAddress;
+
+    @Value("${ctp.printer.bundlePort}")
+    private int bundlePort;
+
+    @Value("${ctp.printer.stitchQRPath}")
+    private String stitchPath;
+
+    @Value("${ctp.printer.bundlePath}")
+    private String bundlePath;
+
     private final BundleDAO bundleDAO;
     private final JobCardDAO jobCardDAO;
     private final MasterBundleDAO masterBundleDAO;
@@ -94,7 +112,7 @@ public class BarcodeService {
             String sizeForStitchItem = BarcodeStickerSize.SIZE_1_X_2.name();
             BarcodeStickerSize stickerSizeForStitchItem = BarcodeStickerSize.getSize(sizeForStitchItem);
             list = stitchingOfflineItemDAO.findByIds(ids);
-            getBarcodeImagesForStitchItems(list, stickerSizeForStitchItem, artifactType);
+            getBarcodeImagesForStitchItems(list, stickerSizeForStitchItem);
         }
     }
 
@@ -107,7 +125,7 @@ public class BarcodeService {
         int cols = 2;
         int totalStickersPerPage = rows * cols;
         int totalPages = (int) Math.ceil((double) artifacts.size() / totalStickersPerPage); // Total required pages
-
+        List<BufferedImage> bufferedImages = new ArrayList<>();
         for (int page = 0; page < totalPages; page++) {
             // Create a Blank A4 Page Image
             BufferedImage a4Image = new BufferedImage(pageWidth, pageHeight, BufferedImage.TYPE_INT_ARGB);
@@ -199,19 +217,62 @@ public class BarcodeService {
                     String concatenatedIds = bundles.stream()
                             .map(bundle -> String.valueOf(bundle.getId()))
                             .collect(Collectors.joining("\\"));
-
                     this.drawCenteredText(g2d, "Sub-Bundles: " + concatenatedIds, detailFont, x, y, pageWidth, cols, stickerSize.getMarginTop() + 290, stickerSize.getMarginLeft());
                 }
 
                 this.drawCenteredText(g2d, String.valueOf(artifact.getId()), detailFont, x, y, pageWidth, cols, stickerSize.getMarginTop() + 330, 0);
             }
-
-            // Finalize Drawing
             g2d.dispose();
-            Path path = FileSystems.getDefault().getPath("./src/main/resources/static/barcode_a4_" + (page + 1) + ".png");
+            bufferedImages.add(a4Image);
-            File outputFile = path.toFile();
-            ImageIO.write(a4Image, "PNG", outputFile);
         }
+        saveA4ImageToPDF(bufferedImages,bundlePath);
+        try {
+            printPDF(bundleIpAddress, bundlePath);
+        } catch (Exception e) {
+            e.printStackTrace();
+        }
+    }
+
+    public void printPDF(String printerIP, String pdfFilePath) throws Exception {
+        File pdfFile = new File(pdfFilePath);
+        FileInputStream fis = new FileInputStream(pdfFile);
+
+        Socket printerSocket = new Socket(printerIP, port);
+        OutputStream out = printerSocket.getOutputStream();
+
+        byte[] buffer = new byte[1024];
+        int bytesRead;
+        while ((bytesRead = fis.read(buffer)) != -1) {
+            out.write(buffer, 0, bytesRead);
+        }
+        out.flush();
+        out.close();
+        fis.close();
+        printerSocket.close();
+    }
+
+    public void saveA4ImageToPDF(List<BufferedImage> a4Images, String outputFilePath) throws Exception {
+        PdfWriter writer = new PdfWriter(outputFilePath);
+        PdfDocument pdfDoc = new PdfDocument(writer);
+        Document document = new Document(pdfDoc, PageSize.A4);
+        document.setMargins(0, 0, 0, 0);
+
+        for (int i = 0; i < a4Images.size(); i++) {
+            if (i > 0) {
+                document.add(new AreaBreak(AreaBreakType.NEXT_PAGE));
+            }
+            ByteArrayOutputStream baos = new ByteArrayOutputStream();
+            ImageIO.write(a4Images.get(i), "png", baos);
+            byte[] imageBytes = baos.toByteArray();
+            ImageData imageData = ImageDataFactory.create(imageBytes);
+            Image image = new Image(imageData);
+
+            // Scale and position correctly
+            image.scaleToFit(pdfDoc.getDefaultPageSize().getWidth(), pdfDoc.getDefaultPageSize().getHeight());
+            image.setFixedPosition(0, 30);
+            document.add(image);
+        }
+        document.close();
     }
 
     private void drawCenteredText(Graphics2D g2d, String text, Font font, int x, int y, int pageWidth, int cols, int marginTop, int marginLeft) {
@@ -224,10 +285,9 @@ public class BarcodeService {
 
 
     public void getBarcodeImagesForStitchItems(List<? extends InventoryArtifact> artifacts,
-                                               BarcodeStickerSize stickerSize,
+                                               BarcodeStickerSize stickerSize) throws Exception {
-                                               String artifactType) throws Exception {
 
-        Path pdfPath = FileSystems.getDefault().getPath("./src/main/resources/static/sample_qr_output.pdf");
+        Path pdfPath = FileSystems.getDefault().getPath(stitchPath);
         PdfWriter writer = new PdfWriter(pdfPath.toFile());
         PdfDocument pdfDoc = new PdfDocument(writer);
         Document document = new Document(pdfDoc);
@@ -242,7 +302,7 @@ public class BarcodeService {
             canvas.rectangle(0, 0, stickerSize.getWidth(), stickerSize.getHeight());
             canvas.fill();
 
-            // Draw QR Code on Left Side**
+            // Draw QR Code on Left Side
             byte[] imgBytes = generateQRCodeImageByteArray(artifact.getBarcode(), stickerSize.getImageWidthBarcode(), stickerSize.getImageHeightBarcode());
             Image qrCodeImage = new Image(ImageDataFactory.create(imgBytes));
 
@@ -253,40 +313,48 @@ public class BarcodeService {
             document.add(qrCodeImage);
 
             float textX = stickerSize.getMarginLeft() + 40;
-            float textY = stickerSize.getMarginTop() +40;
+            float textY = stickerSize.getMarginTop() + 40;
 
             String sku = artifact.getSku();
             String jobCardCode = jobCard.getCode();
             String combinedText = sku + " \\ " + jobCardCode + " \\ " + artifact.getBundleId();
+            combinedText = combinedText.replaceAll("\\s+", "");
 
             int maxLength = 14;
             List<String> lines = new ArrayList<>();
             for (int i = 0; i < 3; i++) {
                 int start = i * maxLength;
                 if (start < combinedText.length()) {
-                    String part = combinedText.substring(start, Math.min(start + maxLength, combinedText.length())).trim();
+                    String part = combinedText.substring(start, Math.min(start + maxLength, combinedText.length())).replaceAll("\\s+", "");
                     lines.add(part);
                 }
             }
 
+            float labelWidth = 67.69f;
+            float textBoxWidth = 220;
             float textY1 = textY-30;
+            float textXCenter = textX + (labelWidth / 2) - (textBoxWidth / 2)-50;
+
             for (String line : lines) {
                 Paragraph rotatedText = new Paragraph(line)
                         .setFontColor(ColorConstants.BLACK)
-                        .setFontSize((float) (stickerSize.getTextSize()+2))
+                        .setFontSize(stickerSize.getTextSize() + 2)
-                        .setTextAlignment(TextAlignment.LEFT)
+                        .setTextAlignment(TextAlignment.CENTER)
-                        .setFixedPosition( textX-48, textY1-18, 220);
+                        .setFixedPosition(textXCenter, textY1-18, textBoxWidth);
 
                 document.add(rotatedText);
                 textY1 -= 6;
             }
 
+            PdfFont font = PdfFontFactory.createFont(StandardFonts.COURIER_OBLIQUE);
             String id = String.valueOf(artifact.getId());
             document.add(new Paragraph(id)
+                    .setFont(font)
                     .setFontColor(ColorConstants.BLACK)
-                    .setFontSize(stickerSize.getTextSize()+6)
+                    .setBold()
+                    .setFontSize(stickerSize.getTextSize() + 8)
                     .setTextAlignment(TextAlignment.LEFT)
-                    .setFixedPosition(textX-21, textY + 10, 140));
+                    .setFixedPosition(textX - 25, textY + 8, 140));
 
             float dottedLine = textY - 60;
             for(int i= 0 ;i<16;i++){
@@ -294,7 +362,7 @@ public class BarcodeService {
                         .setFontSize(stickerSize.getTextSize())
                         .setFontColor(ColorConstants.BLACK)
                         .setBold()
-                        .setRotationAngle(-Math.PI / 2) // ✅ -90 Degree Rotate
+                        .setRotationAngle(-Math.PI / 2)
                         .setTextAlignment(TextAlignment.LEFT)
                         .setFixedPosition(dottedLine,textX+40, 100));
 
@@ -307,17 +375,20 @@ public class BarcodeService {
                         .setFontSize(stickerSize.getTextSize())
                         .setFontColor(ColorConstants.BLACK)
                         .setBold()
-                        .setRotationAngle(-Math.PI / 2) // ✅ -90 Degree Rotate
+                        .setRotationAngle(-Math.PI / 2)
                         .setTextAlignment(TextAlignment.LEFT)
                         .setFixedPosition(dottedLine2,textX+75, 100));
 
                 dottedLine2 += 7;
             }
 
-            if (artifact != artifacts.get(artifacts.size() - 1)) {
+            if (!artifact.equals(artifacts.get(artifacts.size() - 1))) {
                 document.add(new AreaBreak());
             }
         }
+        if (pdfDoc.getNumberOfPages() > artifacts.size()) {
+            pdfDoc.removePage(pdfDoc.getNumberOfPages());
+        }
         document.close();
         sendPdfToZebraPrinter(pdfPath.toFile());
     }
@@ -336,7 +407,7 @@ public class BarcodeService {
         try {
             QRCodeWriter qrCodeWriter = new QRCodeWriter();
             Map<EncodeHintType, Object> hintMap = new HashMap<>();
-            hintMap.put(EncodeHintType.MARGIN, 1); // Optional: control margin size
+            hintMap.put(EncodeHintType.MARGIN, 0);
             BitMatrix bitMatrix = qrCodeWriter.encode(data, BarcodeFormat.QR_CODE, width, height, hintMap);
             BufferedImage qrImage = new BufferedImage(width, height, BufferedImage.TYPE_INT_RGB);
             qrImage.createGraphics().fillRect(0, 0, width, height);
@@ -356,12 +427,41 @@ public class BarcodeService {
         }
     }
 
-    public void printLabel( BufferedImage bufferedImage ) throws Exception {
+    public void printLabel(BufferedImage bufferedImage) throws Exception {
-        Connection connection = new TcpConnection( ipAddress, port );
+        Connection connection = new TcpConnection(ipAddress, port);
         connection.open();
-        ZebraPrinter printer = ZebraPrinterFactory.getInstance( connection );
+
-        ZebraImage zebraImage = new ZebraImage( bufferedImage );
+        ZebraPrinter printer = ZebraPrinterFactory.getInstance(connection);
-        printer.printImage( zebraImage, 0, 0, 0, 0, false );
+
+        //Reset Printer Settings
+        String resetSettings = "^XA^JUS^XZ";
+        printer.sendCommand(resetSettings);
+
+        //Force Label Length & Disable Auto Feed
+        String lengthFix = "^XA^LL555^PON^XZ"; // **Reduce Length (880) & Disable Auto Feed
+        printer.sendCommand(lengthFix);
+
+        //Apply New Settings
+        String settings = "^XA" +
+                "^MMT" +   // Continuous Mode
+                "^MTT" +   // Thermal Transfer Mode
+                "^LH0,0" + // Home Position
+                "^PR6" +   // Print Speed (~120mm/sec)
+                "^MD25" +  // Darkness Level
+                "^PW541" + // Label Width (67.69mm for 203 DPI)
+                "^LL550" + // Reduced Label Length (fix gap)
+                "^PN0" +   // No Extra Page Feed
+                "^PON" +   // Disable Printer's Auto Feed Mode
+                "^XZ";
+
+        printer.sendCommand(settings);
+
+        // Convert BufferedImage to ZebraImage
+        ZebraImage zebraImage = new ZebraImage(bufferedImage);
+
+        // Print image
+        printer.printImage(zebraImage, 0, 0, 0, 0, false);
+
         connection.close();
     }
 }

src/main/resources/application-prod.yml

@@ -32,5 +32,9 @@ spring:
 
 ctp:
   printer:
-    ipAdd: 172.16.53.32
+    ipAdd: 172.16.53.53
-    port: 9100
+    port: 9100
+    stitchQRPath: ./src/main/resources/static/sample_qr_output.pdf
+    bundleIpAdd: 172.16.53.22
+    bundlePort: 9100
+    bundlePath: ./src/main/resources/static/bundle.pdf