Are your product labels silently sabotaging your brand?

It’s not an exaggeration. More than 70% of purchasing decisions are made at the shelf—based largely on how the product looks. This puts a massive spotlight on label printing, yet it’s still one of the most misunderstood parts of product packaging.

Businesses pour energy into perfecting product formulas, packaging designs, and branding, but when it comes to printing those labels? That’s often treated as an afterthought. Choosing the wrong printer, opting for substandard materials, using the wrong ink, or mismatching labels to printers—these are the kinds of oversights that lead to smudges, fading, printer damage, regulatory non-compliance, and thousands of dollars lost to reprints.

That’s where DuraFast Label Company steps in. Known for providing professional-grade solutions for all types of on-demand label printing, DuraFast offers everything from high-end printers and label counter machines to direct thermal labels and ink cartridges for printers that meet industry-specific needs. With decades of expertise, they help businesses avoid the costly mistakes most make and get labeling right from the start.

This blog breaks down the most common label printing mistakes businesses make—and offers practical, proven solutions to fix them. Whether you’re struggling with poor print quality, inconsistent results, or short-lived labels, this is the no-nonsense guide to doing it right.

1. Choosing the Wrong Printer for the Job: A Costly Misstep

Label printing is only as good as the hardware behind it. And yet, one of the most common pitfalls businesses fall into is picking the wrong type of printer for their specific needs. This single decision can create a cascade of problems—from frequent breakdowns to subpar label quality and costly consumables. Let’s take a closer look at how this happens and what you can do to make a smarter choice.

Where Businesses Often Go Wrong

1. Using Desktop Printers for Industrial Workloads

A desktop label printer might look like a smart choice due to its smaller footprint and lower price point. But if your business is printing hundreds or thousands of labels daily—especially for manufacturing, warehousing, or distribution—this kind of unit won’t last. These entry-level models typically lack the durability, speed, and media handling capabilities of an industrial-grade printer.

Overlooking Media Compatibility

Not all printers work with all types of label stock. For example, buying a printer that only supports paper labels when you need synthetic, waterproof, or chemical-resistant labels means your investment is incompatible from day one. This leads to frequent jams, poor print quality, and increased waste—both in time and materials.

Confusing Inkjet vs. Thermal Printing Needs

This is a big one. Inkjet and thermal technologies serve very different purposes:

Inkjet: Best for high-resolution, full-color labels—like those used in retail packaging, product branding, or health & beauty industries. But they’re not ideal for harsh environments or outdoor use unless using specific media and pigment-based inks.

Thermal Printing: Often split into direct thermal and thermal transfer:

·Direct Thermal: Great for short-term uses like shipping labels. No ribbon required, but the print fades over time and with exposure to heat or sunlight.

·Thermal Transfer: Uses a ribbon to create durable, long-lasting images. Ideal for barcodes, compliance labels, and any labels exposed to chemicals or outdoor elements.

Picking the wrong technology can lead to premature fading, smudging, or labels that simply won’t stick or scan.

How to Get It Right

Match the Printer Type to Your Workflow

Before buying, ask yourself:

·How many labels do we print per day?

·Do we need color, or is black-and-white sufficient?

·Will the labels face exposure to water, chemicals, sunlight, or extreme temperatures?

·How long do our labels need to last?

Inkjet Printers: For Vibrant, On-Demand Color

Inkjet printers like the Afinia L502 or Epson C6500 are perfect for small to medium runs of high-quality color labels. Ideal for:

·Custom product packaging

·Seasonal or limited-edition products

·Private labeling

Look for pigment-based ink if durability is a concern, especially for labels exposed to moisture or abrasion.

Thermal Transfer Printers: For Tough, Long-Lasting Labels

These printers are made for industrial environments and are a go-to for:

·Barcode labels for logistics

·UL/CSA compliance labels

·Outdoor label applications

Inventory and asset tracking Use synthetic label stock like polypropylene or polyester for added durability.

Direct Thermal Printers: For Shipping & Logistics

When you need fast, cost-effective label output for items that don’t require long-term durability (like Amazon or USPS shipping labels), a direct thermal printer is the way to go. Just remember—they’re not ideal for outdoor use or extended shelf life.

2. Using Low-Quality Label Materials

Even the best printer can’t save you from using substandard label stock. Labels that peel, fade, or smudge are a fast track to damaged reputation—and sometimes even legal issues in regulated sectors.

Where Businesses Go Wrong:

·Opting for generic label rolls to cut costs

·Using labels incompatible with the printer type

·Ignoring environmental exposure like heat, moisture, or abrasion

Fix It:

Invest in material suited to the product’s environment.

·Non-topcoated direct thermal labels are great for short-term shipping, but not for products exposed to heat or light.

·Topcoated direct thermal labels last longer in tougher conditions.

·Choose labels based on adhesive type, whether you need permanent, removable, or freezer-grade.

·Ask about material certifications for industries like food, pharmaceuticals, and logistics.

3. Using the Wrong Ink or Toner

Matching ink cartridges for printers or toners for label printers to your printer and label stock isn’t just smart—it’s essential.

Ink incompatibility is one of the biggest causes of smudging, poor adhesion, and premature fading. Yet, businesses often opt for third-party cartridges or toners that save money upfront but cost more in the long run due to reprints or damaged printers.

Common Errors:

·Using water-based ink for outdoor or chemical-exposed labels

·Choosing third-party cartridges that don’t meet OEM standards

·Not aligning ink type with label coating (or lack thereof)

Fix It:

·Use pigment-based inks for water-resistant, UV-resistant labels.

·Choose dye-based inks for vibrant colors on indoor-use products.

·Buy OEM-compatible ink cartridges and toners that maintain printer health and label quality.

·Ask suppliers like DuraFast which ink types are best for your printer-label combo.

4. Mismatched Label Size and Printer Configuration

Label misalignment doesn’t just look unprofessional—it leads to wasted rolls, jamming, and mechanical issues. Incorrect media settings can also cause printers to use excess ink or toner.

What Goes Wrong:

·Loading labels of the wrong size for the print head

·Failing to calibrate sensors for label gaps or black marks

·Misconfigured print margins

How to Fix It:

·Always set media size and type in the printer driver and software.

·Perform routine calibrations—especially when switching label sizes.

·Use label counter machines to precisely measure roll length and reduce waste.

·Train staff on proper printer settings and loading techniques.

5. Ignoring Print Durability Requirements

Some labels need to last days. Others need to last years. Too often, businesses don’t factor durability into their print strategy, which leads to fading, peeling, and compliance issues.

Frequent Oversights:

·Using short-term labels for long-term use

·Not testing labels under actual use conditions

·Not understanding industry durability standards (e.g., UL, GHS, BS5609)

The Fix:

·Match label material, adhesive, and ink to your product’s life cycle.

·Test printed labels in real-world conditions—heat, cold, friction, moisture.

·Use thermal transfer labels and resin ribbons for chemical and outdoor exposure.

·Ensure compliance with standards relevant to your sector.

6. Underestimating the Importance of Label Software

The printer is only as good as the software controlling it. Many companies struggle with poor layout design, scaling errors, and inefficient workflows—all because they use outdated or consumer-grade software.

Where Businesses Miss:

·Designing labels in general word processors or image editors

·Skipping barcode validation steps

·Lacking centralized control over multiple printer setups

Recommended Fixes:

·Invest in professional label design software with barcode, database, and RFID capabilities.

·Automate workflows to reduce manual entry errors.

·Integrate label software with ERP systems for real-time inventory and shipping updates.

7. Printing Labels In-House Without Considering Maintenance

DIY label printing offers flexibility—but it also requires upkeep. Businesses often jump into in-house printing without planning for maintenance, which leads to downtime, print errors, and costly repairs.

Problems Arise When:

·Printers aren’t cleaned regularly

·Printheads are damaged by incompatible media or dirt

·Consumables like rollers, cartridges, or toners are neglected

How to Prevent It:

·Schedule regular cleaning of printheads and rollers.

·Use only recommended consumables to protect internal components.

·Keep spare parts and supplies like portable label makers, toner, and ink on hand.

8. Choosing the Wrong Labels for Portable Use

Portable label makers are incredibly useful—especially in fieldwork, healthcare, and inventory tagging. But not every label stock is compatible with handheld or wireless devices.

Mistakes Happen When:

·Businesses choose generic labels that jam small-format printers

·They don’t account for battery life or wireless connectivity

·They opt for low-resolution units unsuited for barcoding

Best Practices:

·Choose the best portable label makers for home use or professional settings based on connectivity, DPI, and label compatibility.

·Use portable label makers with Bluetooth or Wi-Fi for real-time labeling in warehouses, retail, or healthcare.

·Ensure label rolls are specifically sized for the mobile printer model.

9. Overlooking Label Compliance and Regulations

This is especially critical in food, medical, and chemical industries. Inadequate or incorrect labels can result in legal penalties, product recalls, and damaged brand credibility.

Common Oversights:

·Missing mandatory elements (nutrition facts, expiry dates, GHS symbols)

·Poor contrast or unreadable fonts

·Using ink that fades under required conditions

Solutions:

·Familiarize yourself with industry-specific labeling standards.

·Work with a supplier that understands regulatory needs.

·Use the right ink, material, and font sizes to maintain readability and durability.

·Audit your labels periodically for compliance.

10. Not Using Tools That Improve Efficiency and Accuracy

Many businesses still manually count or estimate label usage, resulting in over-ordering, stockouts, or inaccurate label application.

What’s Missing:

·Real-time inventory of printed labels

·Error tracking and waste measurement

·Usage monitoring to manage costs

The Fix:

·Use a label counter machine to monitor usage and calculate cost per label.

·Leverage print management software for batch printing, error logs, and reprint history.

·Use analytics tools to identify inefficiencies in your label printing workflow.

Are These Mistakes Costing Your Business More Than You Realize?

Label printing errors may not seem like a big deal—until they are. One misprint can lead to a product recall. One poorly printed barcode can delay a shipment. One smudged expiration date can spark a regulatory violation.

The good news? These mistakes are entirely avoidable.

DuraFast Label Company provides comprehensive solutions to eliminate every point of failure in the labeling process. From professional-grade printers and high-durability direct thermal labels to compatible ink cartridges and toners for label printers, DuraFast ensures every component works together seamlessly.

They offer one of the widest selections of best portable label makers for home use and business, high-quality non-topcoated direct thermal labels, and label counter machines to streamline operations. With expert consultation, fast shipping, and a deep catalog of equipment and consumables, DuraFast helps businesses produce better labels—faster, cheaper, and more reliably.

If your business is ready to stop wasting time and money on labeling mistakes, now is the time to upgrade your equipment, materials, and processes. Order high-performance printers, toners, and label rolls—or get expert advice on what works best for your application. Whether you’re labeling retail goods, food packages, healthcare supplies, or industrial parts, DuraFast has the solution.

Because the right labels don’t just stick—they sell.