Maximising Labelling Accuracy: Common Mistakes and How to Avoid Them

Labelling is a critical component of packaging, especially in industries like food and beverage, where accuracy ensures compliance with regulations, traceability, and brand consistency. However, even minor mistakes in labelling can lead to product recalls, delays, and increased costs. This blog explores the most common labelling errors and offers actionable solutions to help you achieve seamless application and accuracy.

1. Misaligned Labels

The Problem:

Labels that are skewed, crooked, or improperly placed can affect product aesthetics and readability. Misaligned labels often occur due to equipment calibration issues, inconsistent packaging sizes, or manual application errors.

How to Avoid It:

Automate Application: Use automatic labelling systems that ensure consistent placement.

Calibrate Equipment: Regularly adjust labelling machines to match the size and shape of your packaging.

Test Runs: Conduct test runs to confirm proper alignment before full-scale production.

Pro Tip: Incorporate sensors or camera systems that verify label alignment in real-time, stopping the line if an issue is detected.

2. Incomplete or Missing Labels

The Problem:

A missing or incomplete label can result from equipment jams, roll misfeeds, or operator oversight. This can lead to regulatory non-compliance and product returns.

How to Avoid It:

Inspect Label Rolls: Ensure rolls are properly loaded and check for damage before use.

Monitor Inventory: Keep enough label stock on hand to avoid last-minute changes or shortages.

Automate Inspection: Use systems that detect and reject unlabelled products automatically.

Pro Tip: Train operators to identify early warning signs of roll misfeeds and equip them to troubleshoot quickly.

3. Incorrect Information on Labels

The Problem:

Mistakes in batch numbers, barcodes, or ingredient lists can occur due to data entry errors, outdated templates, or improper integration between systems.

How to Avoid It:

Centralise Data Management: Use software to manage label templates and synchronise data across all production lines.

Automate Data Input: Connect your labelling system to your ERP or database to reduce manual input errors.

Double-Check Updates: Always verify regulatory updates or product changes before they are applied to labels.

Pro Tip: Implement barcode verification systems to ensure accuracy and avoid mislabelled products reaching the customer.

4. Poor Adhesion or Peeling Labels

The Problem:

Labels that peel off or fail to stick can undermine brand presentation and fail to meet compliance standards. Common causes include low-quality adhesives, incompatible surfaces, or extreme environmental conditions like moisture or heat.

How to Avoid It:

Use the Right Labels and Adhesives: Match adhesive properties to packaging materials and environmental conditions (e.g., freezer-safe adhesives for chilled products).

Ensure Clean Surfaces: Dust, grease, or moisture can prevent labels from sticking. Clean and dry surfaces before labelling.

Test Before Scaling: Conduct adhesion tests under production conditions to ensure durability.

Pro Tip: Choose labels designed specifically for challenging environments, such as water-resistant or heat-resistant options.

5. Smudged or Illegible Labels

The Problem:

Blurred or smudged labels are often caused by improper printer settings, poor-quality ink, or mishandling during production. Illegible labels can lead to confusion in the supply chain and regulatory issues.

How to Avoid It:

Optimise Printer Settings: Adjust print speed, temperature, and ink levels to ensure clarity.

Use High-Quality Supplies: Invest in durable inks and ribbons compatible with your printer and packaging material.

Allow Drying Time: Ensure ink is fully dried before products are handled or packed.

Pro Tip: Regularly clean printheads and check for wear to maintain high-quality prints.

Bonus Tip: Train Your Team for Success

Even with the best technology, human oversight remains essential. Provide regular training to your operators and maintenance staff on equipment handling, troubleshooting, and quality control. Educated teams can spot potential problems early and keep production running smoothly.

Summary

Labelling accuracy is vital for maintaining brand integrity, ensuring regulatory compliance, and enhancing operational efficiency. By addressing common issues like misalignment, missing labels, incorrect data, poor adhesion, and smudging, you can create a streamlined, error-free labelling process.

Adopt automation, use the right materials, and invest in training and quality control systems to maximise accuracy and reliability in your labelling operations. With these practices in place, you’ll not only save time and costs but also ensure your products consistently make a strong impression on the market.

For tailored guidance on coding and labelling technology Contact us today at Industrial Printer Services Ltd, and we can assess your specific needs and recommend the best equipment for your industry and substrate.