In the world of product manufacturing, packaging, and distribution, labels may seem like a small detail—but they carry big consequences. A poorly performing label can disrupt supply chains, damage brand reputation, and even lead to regulatory issues. If you’ve ever had to re-label thousands of items because the original ones peeled off or faded, you already know how costly those mistakes can be.
In this blog, we’ll explore common label failures, the real-world costs associated with them, and how South African businesses can protect themselves by choosing the right labelling solutions from the start.
The Hidden Costs of Label Failures
When a label fails, it’s not just the label that needs replacing. There are ripple effects that impact multiple departments across a business. Operational delays are one major issue; when barcodes or product info are unreadable, warehouses slow down because scanning systems can’t verify items, leading to costly downtime. In industries like pharmaceuticals and food, incorrect or missing label data can trigger full-scale product recalls, which are not only expensive but can severely impact brand credibility. Reputational damage also follows when customers receive poorly labeled or misidentified products—trust is lost, sometimes permanently. Finally, regulatory fines come into play when businesses fail to meet labelling standards, such as providing accurate dosage information or allergen warnings. These issues are not uncommon; a recent study by Packaging South Africa found that labelling errors and non-durable materials were among the top causes of compliance violations in the food and cosmetic sectors.
Top Label Failures and Their Causes
Let’s break down the most common types of label failures and what typically causes them:
Peeling or Lifting Labels
This occurs when a label doesn’t adhere properly to the surface it’s applied to. The main culprits usually include using an incorrect adhesive for the material or temperature range, contamination on the application surface such as dust, moisture, or oil, and poor surface compatibility with materials like textured plastic or low-energy substrates.
Fading or Smudging Ink
Faded labels become unreadable over time, while smudged labels look unprofessional and reduce trust. This often results from UV exposure, heat, and humidity, which degrade the print. Low-quality ink or incorrect printing methods can exacerbate the problem, particularly when paper labels are used in high-moisture environments without protective lamination.
Misaligned or Misprinted Labels
Misalignments can cause barcodes to be unreadable or text to be cut off. This issue is frequently due to poor calibration during printing, inconsistent label stock or machine jams, and a lack of quality control during production runs.
Label Shrinkage or Expansion
Labels that expand or shrink after application can distort graphics or loosen their hold. This is typically caused by thermal exposure or the use of incompatible materials, along with poor adhesive selection that doesn’t account for potential material movement.
Non-Compliance with Industry Standards
Each industry has its own set of labelling regulations, especially the food, chemical, and pharmaceutical sectors. Common failures include using incorrect font sizes, omitting required safety warnings, or providing poorly translated text. These problems often stem from outdated templates or a failure to stay informed on updated regulations.
Real-World Examples: When Labels Go Wrong
The Beverage Company Recall
A local juice brand faced a costly recall after label adhesives failed in refrigeration conditions. The labels peeled off, making the products non-compliant with retail barcode scanning systems. Not only were they pulled from shelves, but the brand had to reprint and relabel thousands of units, damaging retailer relationships.
Pharmaceutical Warning
A pharmacy chain received a warning from the Department of Health after customer complaints about unreadable dosage instructions on medication bottles. The cause? Low-contrast printing on glossy surfaces without protective coating, which smudged over time. The issue cost the brand a compliance penalty and required an overhaul of their labelling materials.
How to Avoid Label Failures: A Step-by-Step Guide
Avoiding label failure starts with asking the right questions and working with a reliable labelling partner. Here’s a roadmap for businesses looking to eliminate label risks:
1Choose the Right Adhesive and Substrate Combo
Not all adhesives are created equal. Depending on whether your products are stored in cold rooms, exposed to sunlight, or shipped across rough terrain, you’ll need freezer-grade adhesives for cold environments, aggressive permanent adhesives for rough or oily surfaces, and removable adhesives for products that require temporary labelling.
Invest in High-Quality Print Methods
Inkjet and laser printing aren’t always enough. For durability, it’s wise to use thermal transfer printing for high-resolution, long-lasting text and barcodes. You should also consider UV-resistant inks and coatings, and ask about lamination or varnish for added protection against moisture and abrasion.
Test, Test, Test
Before rolling out new labels, run adhesion tests under real-life conditions. Expose labels to light, moisture, and heat to evaluate their performance. It’s also a good idea to get samples printed and field-tested with your supply chain partners to catch potential issues before full deployment.
Partner with an Experienced Label Supplier
Work with a supplier who understands your industry. At Libra Labels, our team evaluates your needs and recommends the perfect combination of materials, adhesives, and finishes—all backed by rigorous quality assurance practices.
Stay Updated on Regulations
Laws evolve, especially in sectors like food safety and pharmaceuticals. Assign someone in your team to monitor labelling standards, or work with a supplier like Libra that proactively updates clients on regulatory changes.
Why South African Businesses Trust Libra Labels
At Libra Labels, we combine technical expertise with world-class printing capabilities to ensure every label performs exactly as intended. Whether you’re in fast-moving consumer goods, healthcare, or manufacturing, our team delivers industry-specific advice, customisable solutions, rapid turnarounds, and consistent quality.
We use advanced technology, from flexographic and digital printing to specialty adhesives and coatings, to help your labels not only look great but last.
Our approach is simple: we listen, we test, and we deliver. That means fewer failures, better brand perception, and smoother operations.
Final Thoughts
Labels might be small, but their impact is massive. A poorly chosen label can cost your business in time, money, and reputation. But with the right labelling partner, you can avoid all that.
Whether you’re launching a new product, scaling production, or rethinking your packaging, don’t let your labels be an afterthought. Partner with experts who treat labels like what they truly are: critical components of your product’s success.
Need help getting it right? Contact Libra Labels today for a tailored labelling solution that works just as hard as you do.