Why Label Failures Happen: TIP #3

Q: When A Customer Says Their Labels Are Failing What’s Your First Reaction?

A:  “When they say their labels are failing first thing I would like to know is what type of decorating method are they using. Are they using adhesive based stickers, are they using pad printing or screen printing. I want to understand what they’re currently doing in their process.  It’s important to listen.

It’s helpful to know how often these failures are occurring and what the impact it’s having to their products. Is this impacting their manufacturing process or is this something that is happening in the field and causing a problem to either the end users or consumers.

Once we understand what they are doing and how it’s impacting the final product, we can get to the root cause and potentially offer a solution.”

Q: Can You Share An Example Where That Deeper Look Led To Surprising Savings?

A:  “Yes, there was a reusable packaging company that had bar codes that were being able to track their assets. It turns out the labeling method was working fine during manufacturing but we were able to uncover that the tag in this case a linear bar code was being separated from the asset itself in the field. It wasn’t that the pallet stopped working that was the issue. We were able to uncover the bigger issue which was a lost inventory tag. Whether it’s a linear bar code or a 2D data matrix is only effective if it stays with the asset that it’s designed to track.”

Q: Have you seen label issues lead to liability or safety risks?

A:  ” Yes a big portion of our business is surrounding warnings and cautions.  Many times the warnings are intended to stay with the product for the life of the product instructing people on operation and safety concerns.

We have a case study on our website regarding shopping cart warnings and the fact that the hot stamp foil was failing on the leg hole closures. I would encourage everyone to read that case study because that defect certainly opened that company up to potential liability”

Q: Are There Hidden Costs In Labeling That Customers Sometimes Overlook?

A:  “Hidden factory is key to understanding total cost.  All that means is to look at the entire manufacturing process looking for waste that doesn’t add value to the product.  For example, bottlenecks that lose time.  Added steps that could be eliminated like flame treating or plasma treating. Wasted hot stamp foil due to improper spacing. Often times we can save companies a great deal of money by investigating Hidden Factory.”

Q: Some companies are concerned about upfront label costs. What do you tell them?

A:  “I walk them through what their current process is really costing…

Replacing failed labels. Retouching worn warnings. Losing trackable assets. Paying for rework, complaints, or safety audits.

Polymer Fusion Labels might cost more upfront, but they eliminate those hidden costs.”

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When companies take a closer look at why their labels are failing, they often discover it’s more than a cosmetic issue. It’s affecting traceability, compliance, product safety, and even customer trust.

At Polyfuze, we don’t just sell labels. We help our customers solve problems that impact their business. Whether it’s for reusable packaging, medical waste, automotive components, or consumer goods, Polymer Fusion Labels are built to last and designed to protect your products, your people, and your reputation.

Visit or contact Polyfuze Graphics Corporation today.