Labelling Solutions The hidden cost
of poor labelling: Why print quality matters more than ever
I
t’s easy to underestimate the importance of a label because it appears to play such an insignifi cant part of the overall product or shipment process. However, in today’s automated supply chains, the label often determines whether an operation runs smoothly or grinds to a halt.
A barcode that cannot be scanned on the
fi rst attempt, or an RFID tag that doesn’t encode correctly, can interrupt automated sorting, delay shipments, trigger manual intervention and even lead to compliance issues. These seemingly minor failures quickly add up to lost productivity, increased labour costs, potential chargebacks or fi nes, dissatisfi ed customers and possible reputation damage.
As businesses increasingly adopt warehouse automation, robotics and technologies like RFID, label quality is becoming a critical part of operational effi ciency rather than simply a printing consideration.
And many of the issues don’t even start with the printers, they begin much earlier in the process.
For 1D and 2D barcode labels, common problems include insuffi cient print contrast, incorrect print darkness, poor media selection or labels that become damaged in demanding environments such as cold storage, manufacturing or logistics.
With RFID, media design becomes equally important. Incorrect inlay positioning, inconsistent pitch or unsuitable label construction can reduce encoding reliability and reading performance. And many of these problems only become apparent once labels have been applied. When products fail to scan at receiving, inventory counts become inaccurate or automated systems reject items. By that stage, the cost of correcting the problem is signifi cantly higher than preventing it during label production.
WHAT DOES POOR PRINT QUALITY COST? Compliance demands are rising. Inaccurate, unreadable or badly formatted barcode labels look unprofessional and can cost manufacturers rejected shipments, fi nes and even reputation damage.
In normal operation, 99.9 per cent of barcode labels will print just fi ne but that means one in 1,000 is grading below specifi cation. If taken over a month’s production, printing 5,000 labels a day, 100 labels could be failing. Assuming compliance fi nes are $20+ per label—not uncommon in the US—manufacturers could be coughing up $2,000 per month in chargebacks.
HOW TO STOP ‘BAD’ LABELS BEFORE THEY REACH PRODUCTION
The best approach is to treat label quality as part of the overall production process rather than the fi nal step.
Select media that is suitable for the application and validate it under real operating conditions. Barcode quality should be verifi ed consistently to ensure labels meet industry standards. With RFID, test labels for encoding reliability before large production runs.
Companies like TSC Auto ID support these processes with technologies such as integrated barcode verifi cation and RFID Auto-Calibration. Barcode verifi cation checks that printed codes are readable before they leave the printer, and overstrikes any off ending/non-complying labels and replaces them automatically. This helps identify defects immediately instead of after products have entered the supply chain. The cost of a barcode verifi er like TSC’s ODV could easily be recouped by avoiding just one fi ne. For RFID, Auto-Calibration automatically
determines the optimal encoding settings for a wide range of approved inlays, reducing manual setup and helping deliver consistent encoding performance. Such capabilities help businesses reduce waste, minimise rework and improve fi rst- time printing accuracy.
PREPARING FOR THE CHANGING ROLE OF LABELS
Labelling is evolving, from simply identifying products to enabling digital supply chains. Global initiatives like GS1 Sunrise 2027, increasing RFID adoption and upcoming Digital Product Passport requirements mean labels will carry much more data and play a greater role in traceability, inventory visibility and compliance. Converters and manufacturers should therefore think beyond today’s requirements and invest in fl exible labelling solutions that can support both traditional barcodes and RFID technologies as their operations evolve.
Choosing scalable printers, validated media and built-in quality assurance tools allows organisations to adapt more easily to new regulations and customer expectations without having to redesign their entire labelling infrastructure.
Ultimately, the goal isn’t just to print labels but to ensure every label performs reliably throughout the entire supply chain. If you think your operation could benefi t from integrated barcode verifi cation and RFID Auto-Calibration or from more scalable printers then contact TSC.
20
July/August 2026
www.convertermag.com
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