Shipping labels seem simple until something goes wrong — a barcode won’t scan, a label peels off in transit, or a whole batch prints out smudged right before a big order needs to go out. These issues are more common than most businesses expect, and they usually come down to a handful of root causes: the printer, the label material, or the way labels were produced in bulk.
Here’s a look at the most common shipping label problems, why they happen, and how to fix or avoid them.
1. Barcodes That Won’t Scan
The problem: A carrier or warehouse scanner can’t read the barcode, which can delay a shipment or cause it to be flagged for manual processing.
Why it happens: This is usually caused by low print resolution, a barcode printed too small, smudged ink from a printer running low on toner, or poor contrast between the barcode and the label background.
The fix: Make sure barcodes are printed at a high enough resolution and size to scan reliably, and always test a sample label before running a full batch. If you’re printing unique barcodes, tracking numbers, or serial numbers across a large batch of labels, this is exactly what variable data printing is built for — Quadlabels can print a different barcode, serial number, or lot code on every single label in a bulk run, so each one is accurate and scan-ready without manually updating a print job for each label.
2. Labels Peeling Off or Falling Off Packages
The problem: A label starts lifting at the edges or falls off entirely before a package reaches its destination.
Why it happens: This is almost always an adhesive or material issue — using a general-purpose label on a box that gets exposed to moisture, cold, rough handling, or extended transit time.
The fix: Match the label material to the shipping conditions. Packages headed for humid environments, refrigerated shipping, or long-distance freight need a more durable, weather-resistant label material rather than a standard paper label. Ordering labels from a printer that offers multiple material options makes it easier to pick the right one for each type of shipment instead of using the same label for everything.
3. Faded, Smudged, or Inconsistent Print Quality
The problem: Labels print unevenly — some are crisp, others come out faded or streaky, especially in the middle of a large batch.
Why it happens: In-house thermal printers can produce inconsistent results as the print head wears down, or if the label stock isn’t well matched to the printer. This becomes more noticeable the larger the print run gets.
The fix: For small batches, keeping printer heads clean and using printer-matched label stock helps. But for large, recurring print runs where consistency really matters — product labels, packaging labels, or high-volume shipping labels — ordering pre-printed labels in bulk from a dedicated label printing company avoids the problem altogether, since professional print equipment is built to maintain consistent quality across large runs.
4. Wrong Label Size or Placement
The problem: A label is too big for the box, hangs off the edge, or covers a barcode or return label that a carrier needs to see.
Why it happens: This typically comes down to using a label size that doesn’t match the packaging, or not accounting for placement when designing the label layout.
The fix: Standardize label sizes and placement guidelines across your packaging so there’s no guesswork during a rush shipment. If you’re ordering labels in bulk, working with a printer that can produce custom sizes means you’re not stuck adapting your packaging to fit a limited set of standard label dimensions.
5. Printer Downtime and Running Out Mid-Batch
The problem: A printer jams, runs out of labels, or needs maintenance in the middle of processing a large batch of orders — right when you can least afford the delay.
Why it happens: In-house printers are doing double duty as both your everyday tool and your bulk production line, so it doesn’t take much (a paper jam, a worn print head, an empty roll) to bring shipping to a halt.
The fix: For businesses shipping high volumes regularly, relying entirely on a single in-house printer for bulk needs is a risk. Ordering product or shipping labels in bulk ahead of time — rather than printing every label on demand — removes the daily printer from being a single point of failure for your fulfillment process.
6. Labels That Don’t Hold Up in Storage or Transit
The problem: Labels look fine when applied but fade, smear, or degrade by the time a package arrives, especially after sitting in a warehouse or truck for an extended period.
Why it happens: This usually comes down to using a lower-grade material or finish that isn’t built to withstand light exposure, humidity, or handling over time.
The fix: For labels that need to survive longer shipping times or storage conditions, a more durable material or protective finish makes a real difference. This is where working with a label printing company that offers a range of material and finish options is useful — you can choose the right combination for the specific durability your product or shipment needs, rather than defaulting to whatever a standard printer roll happens to offer.
When It’s Time to Stop Troubleshooting and Order in Bulk
A lot of these problems share the same root cause: trying to stretch an everyday in-house printer to cover high-volume, recurring label needs. That works fine at a small scale, but as order volume grows, the cost of misprints, downtime, and inconsistent quality adds up fast.
Quadlabels produces bulk product, packaging, and shipping labels — from as few as 100 up to runs in the millions — with a standard production turnaround of just 3-5days. With a wide range of materials and finishes available, along with variable data printing for labels that need unique barcodes, serial numbers, or tracking details, it’s built to solve exactly the kind of problems outlined above before they happen.
Getting Started
If shipping label issues are slowing down your fulfillment process, you can create an account and submit a bulk order directly through Quadlabels’ online ordering portal. Choose your label size, material, finish, and quantity based on your shipping requirements, and place your order when you’re ready.
Ordering in bulk can help reduce the need for frequent in-house printing while keeping your labels consistent from one shipment to the next. If you’re unsure which material or finish is right for your packages, Quadlabels can help you choose an option suited to your shipping and storage conditions.
