Common Mistakes with Pallet Labelling (and How to Solve Them)

In busy manufacturing and warehouse environments, pallet labelling can sometimes be treated as an afterthought. But anyone who’s dealt with a rejected shipment or a misrouted pallet knows just how critical accurate labelling really is.

Get it right, and your pallets move smoothly through the supply chain - scanned, tracked, and received without issue. Get it wrong, and you’re looking at delays, rework, or worse, compliance headaches.

At Industrial Printer Services Ltd, we work with manufacturers, logistics providers, and warehouses across the UK to help them avoid exactly these problems. And after years of supporting pallet labelling systems, we’ve seen the same few mistakes crop up time and time again.

Here’s what they are - and how to fix them.

Why Pallet Labelling Matters More Than You Think

Your pallet label isn’t just a sticker - it’s the passport that keeps your product moving. It ensures each pallet can be identified, scanned, and traced at every step of its journey.

Accurate, compliant pallet labelling helps you:

  • Maintain traceability throughout your supply chain
  • Meet GS1 pallet labelling standards for compliance
  • Streamline warehouse automation and scanning processes
  • Reduce manual errors and shipping delays

When labels are printed, placed, and managed correctly, everything downstream - from logistics to customer deliveries - works better.

The Most Common Pallet Labelling Mistakes (and How to Fix Them)

1. Labels Placed in the Wrong Position

It’s one of the simplest mistakes, but still one of the most common. Labels that are placed too high, too low, or under shrink wrap can’t be read reliably by scanners.

The fix:

Follow GS1 guidelines for pallet label placement - on flat, smooth surfaces on two adjacent sides, ideally 400–800 mm from the base. Automated print and apply systems ensure every label goes in the right place, every time.

2. Poor Print Quality or Faded Barcodes

Blurry or faded barcodes are a nightmare for warehouse teams. Low-quality ribbons, dirty printheads, or incorrect settings can all lead to unreadable labels.

The fix:

Use high-quality thermal ribbons and industrial-grade labels designed for your printer. Schedule regular maintenance and calibration. At Industrial Printer Services Ltd, we also recommend thermal transfer print and apply systems for long-lasting, high-contrast results.

3. Non-Compliance with GS1 Standards

Retailers and logistics hubs rely on GS1 compliant pallet labels to identify and track goods. If your labels don’t include the correct SSCC code or barcode format, your pallets could be rejected.

The fix:

Use label management software that automatically formats to GS1 standards. We often help customers integrate validation checks into their pallet labelling systems, eliminating manual data entry errors.

4. Manual Data Entry and Poor Integration

Typing label data by hand seems simple - until one digit is off and your pallet is linked to the wrong order.

The fix:

Integrate your pallet labelling system with your ERP, MES, or WMS. That way, label data flows directly from your production or dispatch systems, ensuring complete accuracy and traceability.

5. Using Labels Unsuitable for the Environment

If labels peel off in the cold store or smudge in humid conditions, you’ll struggle to maintain visibility across your supply chain.

The fix:

Select label materials and adhesives designed for your working environment - whether that’s a freezer, a dusty warehouse, or an outdoor loading bay. Our team at Industrial Printer Services Ltd can help you test and specify the right materials for your needs.

6. Skipping Regular Maintenance

Even the best print and apply labelling systems need occasional attention. Without maintenance, print quality drops, labels misalign, and downtime increases.

The fix:

Plan regular servicing and cleaning. Our engineers provide full printer maintenance and support services, ensuring your systems stay reliable and efficient year-round.

How to Strengthen Your Pallet Labelling Process

If you’re looking to tighten up your operation and eliminate label-related errors, here are a few proven strategies:

  • Automate with industrial print and apply labelling systems
  • Implement barcode verification before pallets leave your sit
  • Standardise label templates and data sources across production lines
  • Integrate label management software with your ERP or WMS
  • Work with a trusted partner like Industrial Printer Services Ltd for setup, service, and ongoing support

When your pallet labelling process is accurate, compliant, and consistent, you’ll spend less time fixing problems and more time keeping production moving.

Summary

At the end of the day, good pallet labelling isn’t just about ticking boxes for compliance - it’s about making your supply chain run smoother, faster, and smarter.

If you’ve experienced issues with label placement, print quality, or GS1 compliance, it’s worth reviewing your current setup. The right pallet labelling system, backed by expert service, can save you time, money, and a lot of frustration.

At Industrial Printer Services Ltd, we help businesses implement reliable pallet labelling, product coding, and case coding solutions, along with full support and maintenance services. If you’d like to review your current system or explore automation options, our team would be happy to help.

Contact us today to arrange a pallet labelling consultation or service audit.

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