How To Reduce Label Breakage Rates?

Last updated May 29, 2024

Label roll

In the world of packaging and production, label breakage rates can be a significant bottleneck, impacting operational efficiency and product integrity. Reducing these rates is not only critical for maintaining product quality but also for enhancing customer satisfaction and compliance with regulatory standards.

This article explores practical strategies and innovations in technology that can help minimize label damage during the manufacturing and application processes.

Selecting the right label materials

  • Durability of materials: The choice of label material plays a crucial role in its susceptibility to damage. Materials like polyester and polypropylene offer higher resistance to environmental factors such as moisture and heat, making them ideal for harsh conditions.
  • Environmental considerations: It’s important to select label materials that are suited to the specific conditions they will encounter. For example, labels used in outdoor environments should have UV-resistant qualities to prevent fading and degradation.

Optimizing adhesive performance

  • Choosing the correct adhesive: The type of adhesive is pivotal in label application. Permanent adhesives are suitable for labels that should not be removed, whereas repositionable adhesives allow for some adjustment after application, reducing the risk of breakage during initial placement.
  • Adhesive testing: Conducting thorough tests on adhesives under various environmental conditions can ensure that the chosen adhesive performs well throughout the product’s lifecycle.

Maintenance and calibration of labeling machinery

  • Regular maintenance: Keeping labeling machinery well-maintained is essential to prevent label tearing or misapplication. This includes regular lubrication of moving parts, checking sensor alignment, and replacing worn-out components.
  • Machine calibration: Calibrating labeling machines to ensure that they apply the correct pressure and accurately place labels can significantly reduce the incidence of label breakage.
labeling machine

Monitoring labeling processes

  • Real-time monitoring with vision systems: Implementing advanced vision systems can help detect and alert operators to issues with label applications in real time, allowing for immediate adjustments.
  • Data analysis for continuous improvement: Collecting and analyzing data from the labeling process can identify patterns leading to label breakage, informing necessary adjustments in machine settings or operations.

Training for operators

  • Comprehensive training programs: Proper training for operators on how to use and troubleshoot labeling machines is vital. Well-informed operators can prevent many issues that lead to label damage.
  • Quality awareness sessions: Educating staff about the impact of label quality on customer satisfaction and regulatory compliance can motivate adherence to best practices in labeling.

Implementing quality control measures

  • Establishment of quality standards: Setting clear quality standards for label application helps ensure consistency. Regular inspections and adherence to these standards can reduce error rates and subsequent label damage.
  • Quality improvement initiatives: Using feedback from quality control inspections to initiate improvements in the labeling process supports a culture of continuous improvement.

Packaging and transportation

  • Protective packaging design: Designing packaging that protects labels during shipping and handling can prevent damage. Consider buffer materials that shield labels from impact and compression.
  • Optimized transportation conditions: Ensuring that the transportation of labeled products does not expose them to conditions that could degrade labels is crucial. This might involve climate-controlled transport environments.
packaging line


Efficiently managing label breakage rates is essential for maintaining the integrity of products and the satisfaction of end-users. By choosing the right materials, optimizing machinery, implementing rigorous quality controls, and ensuring thorough training and monitoring, companies can significantly reduce the incidences of label damage.

As technology advances, adopting innovative solutions like smart sensors and AI-driven systems will further enhance the precision and resilience of labeling operations, keeping label breakage rates to a minimum and supporting sustainable business practices.

Viallabeller is a pioneer in this field. As a pharmaceutical labeling machine company, the label loss rate of our products is < 0.1%.

Our products include the following solutions for various pharmaceutical labeling:

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