Common Sealing and Labeling Mistakes and How to Avoid Them

Even experienced operations stumble over simple issues in Sealing and Labeling. Small mistakes can cascade into lost shipments, unhappy customers, or regulatory penalties. This beginner-friendly article highlights common errors, why they happen, and how to avoid them with practical, friendly advice.

Mistake 1: Poor seal integrity

Problem: Packages burst open or are damaged in transit because tape, seals, or closures were inadequate. Why it happens: using low-quality tape, applying insufficient tape, or failing to account for weight and handling risks.

Prevention

• Use industry-standard tape for carton sealing and follow the three-strip or H-taping method for heavy loads.
• Choose seal types appropriate to weight and product fragility (strapping, hot-melt, or tamper seals for high-value items).
• Inspect random samples regularly to find weak seals before shipments leave.

Mistake 2: Unreadable or poor-quality barcodes

Problem: Scanners fail to read barcodes, causing manual entry errors and delays. Why it happens: wrong printer settings, low-contrast printing, creased labels, or placing labels over seams.

Prevention

• Use thermal transfer printing for long-lasting, high-contrast barcodes if exposure to heat or sunlight is likely.
• Verify barcode quality with a verifier and use clear label placement rules (no seams, folds, or straps).
• Ensure labels are within printer resolution requirements for the barcode density (dpi).

Mistake 3: Incorrect or incomplete label information

Problem: Wrong item shipped, customs delays, or returns due to missing or incorrect details. Why it happens: manual data entry, unclear templates, or lack of cross-checks.

Prevention

• Integrate labeling with your WMS or order system so labels are auto-populated from order data.
• Use checklists and a two-person verification step for high-risk shipments.
• Standardize label templates and train staff to recognize required fields (SKU, lot, expiration, destination).

Mistake 4: Ignoring regulatory labeling

Problem: Fines or shipment rejections because hazard symbols, country-of-origin marks, or customs declarations are missing or incorrect. Why it happens: unfamiliarity with regulations or assuming one-size-fits-all labeling.

Prevention

• Keep an up-to-date compliance checklist for products that require special marks (hazmat, food, medical).
• Consult carriers or customs brokers for international requirements and harmonized code guidance.
• Use pre-printed regulatory labels when required and ensure legibility and placement meet standards.

Mistake 5: Wrong label placement

Problem: Scanners can’t find labels, or labels are damaged during handling. Why it happens: inconsistent placement, labeling over corners or straps, or small packages without flat surfaces.

Prevention

• Define and enforce clear placement zones on common box sizes and pallet faces.
• For odd-shaped items, create guidelines (e.g., attach a secondary label on the outer package).
• Use label holders or pouches for documents and fragile tags that need protection.

Mistake 6: Overlooking environmental factors

Problem: Labels peel off or fade due to moisture, cold, heat, or sunlight. Why it happens: using the wrong adhesive or label material.

Prevention

• Choose label stock and adhesives rated for the environment (cold-temperature adhesives for frozen goods, weatherproof labels for outdoor transit).
• Test labels in the actual conditions you expect (e.g., freezer, humid warehouse).

Behavioral and process mistakes are common but fixable. Lack of training, inconsistent procedures, and skipping quality checks invite errors.

Solutions include:

• Regular, brief training sessions with visual aids and quick quizzes to keep standards top-of-mind.
• Daily spot checks and a feedback loop where packers can report issues with materials or templates.
• Maintaining a small toolkit at each station: spare labels, a tape roll, a barcode verifier app, and an SOP sheet.

Real-world example

A midsize e-commerce company reduced mis-shipments by 70% after they automated label generation from their WMS, switched to thermal transfer labels, and required a one-minute seal-and-label verification before orders left packing. The investment was modest, and benefits included fewer customer complaints and faster carrier handoffs.

In short, many sealing and labeling errors stem from mismatched materials, inconsistent procedures, or a lack of cross-checks. By standardizing processes, choosing the right materials, and training staff, even small operations can avoid common pitfalls and enjoy smoother, more reliable shipping operations.