Most label failures happen before you press print, but finding out afterwards will cost you. Avoid these four mistakes to save your team time and money.
TLDR:
- Match your stock to the layout your carrier generates
- Check the roll core fits your printer's spindle
- Use direct thermal for parcels delivered within days, thermal transfer for anything stored
- Print barcodes solid black, with clear space, on a flat surface
A faulty shipping label stops the parcel moving until someone re-labels it.
Dial A Label has made labels in Melbourne for more than 30 years, long enough to see the same mistakes again and again. Here’s what to avoid.
Mistake #1: Ordering labels before checking what your carrier generates
Your shipping platform produces the label in a fixed layout. Order stock and set up your printer to suit that layout. Don’t resize the label to fit a roll you want to use up.
Use the table below to match the roll to your platform’s output, then print at actual size. Browser and PDF scaling shrinks barcodes and shifts text, which can stop them from scanning.
Which shipping labels do I need?
| Dial A Label product | Typical use | Courier* |
|
100 x 150 mm direct thermal roll |
Everyday courier and dispatch | Aramex; Australia Post; StarTrack |
| 105 x 150 mm roll or fanfold | High-volume dispatch on externally fed printers; closest to A6 | Aramex; Australia Post; StarTrack |
| A4 laser sheets, 1UP to 4UP | In-house laser or inkjet printing | Aramex; Australia Post |
| 104 x 175 mm roll | Connotes and integrated freight | Any |
*Note: Some couriers support more than one size, so check before you order.
Mistake #2: Ordering a roll your printer cannot take
The core, the cardboard tube at the centre of the roll, decides whether it fits your printer’s spindle. Getting it wrong is one of the most common reasons labels go unused.
We supply freight labels on 19 mm, 25 mm, 38 mm and 76 mm cores, plus fanfold for externally fed printers. Desktop printers usually take a 25 mm core, while midrange printers usually take 76 mm.
Larger cores usually hold more labels, so you’ll reload less often.
Read more: How to choose the right label printer for your business
Unsure which labels to reorder?
If you don’t have a record of your last order, measure two things: the label face (width first, then length, ignoring the backing) and the inside diameter of the core.
Mistake #3: Choosing the wrong label for the journey
Direct thermal is the default for courier labels because parcels are scanned and delivered well before the print starts to fade. Anything that will sit in storage needs thermal transfer.
Direct thermal prints without a ribbon. The printhead darkens a heat-sensitive coating on the label. Heat, light and abrasion fade the print over months, which won’t matter for a parcel going straight out.
Thermal transfer uses a ribbon, a roll of inked film. The printhead melts the ink onto the label, so the print lasts much longer. That makes it the right choice for export cartons and freight held in yards or cold storage.
Read more: Direct thermal vs thermal transfer labels: what’s best for your business?
Why do labels peel off parcels?
Poly satchels stretch and wrinkle, recycled cardboard sheds dust, and cold or damp surfaces weaken the adhesive. For chilled or frozen goods, ask for cold temperature or freezer stock.
Mistake #4: Overlooking barcode quality and placement
A barcode needs clear space around it, solid black print and a flat surface. Most scan failures trace back to one of these.
Leave a quiet zone (a blank margin) around the barcode and print nothing behind it. Never shrink or stretch it to fit the space.
Faded or streaky print usually points to cheap label stock, a worn printhead or a low heat setting. Most label printers run at 200 dpi (dots per inch), which is enough for barcodes and addresses. Small text and logos may need a higher-resolution printer.
Apply the label flat, facing outward, on the largest face. Keep clear of seams, tape, edges and corners. On a reused carton, cover the old barcode completely.
Sorting express and priority freight
Packers sort by sight, so colour separates express and priority consignments faster than text. Our yellow direct thermal stock comes in 100 x 150 mm and 105 x 150 mm and runs on the same printers as your white rolls.
We also stock dedicated white StarTrack Express freight labels. Check your carrier's requirements before moving a service onto coloured stock.
Barcode won’t scan? Check these first
- Are you printing at actual size, with scaling turned off?
- Is the printer set to the label size you’ve loaded?
- Are your barcodes solid black, not grey or patchy?
- Is there clear space around the barcode?
- Is the label flat and clear of seams and edges?
Check these before your next run
Before you order, check that your stock matches your carrier’s layout and your printer’s core, and decide whether the job needs direct thermal or thermal transfer. After printing, make sure the barcode is solid black, has clear space and sits flat.
Dial A Label is your go-to partner for shipping labels. Our Melbourne-based team can guide you through the label selection and printing process, helping you choose an approach that suits your courier, budget and goals.
To learn more or request a quote, email us at labels@dal.com.au or call (03) 9764 2882.