The Downsides of Manual Labeling: Efficiency and Challenges

Having an efficient labeling process is crucial for packaging operations in every industry. Proper labeling not only ensures regulatory compliance but also plays a vital role in product presentation and brand image. The labeling process influences how consumers perceive a product, impacting their purchasing decisions and overall satisfaction. Well-applied labels can convey quality and professionalism, while poorly applied ones can detract from a product's appeal and trustworthiness. However, many companies, even large ones, continue to rely on manual labeling methods, which creates challenges. By embracing automated label applicator machines, businesses can streamline their labeling processes, ensure consistent and high-quality label applications, and better position themselves for sustained growth and success in the marketplace.

The Operational Challenges of Manual Labeling

Manual labeling means that you apply labels to products by hand. While this method may seem straightforward, it brings several challenges that can hinder business operations. These challenges impact more than just the immediate labeling process, affecting overall workflow, resource allocation, and operational efficiency.

Labor-Intensive Nature

The labor-intensive nature of manual labeling significantly impacts labor costs and resource allocation. Businesses must allocate substantial manpower to the labeling process, diverting valuable human resources from other critical tasks. This can lead to increased payroll expenses and the need for ongoing training and supervision. Additionally, maintaining consistent label placement and alignment can be challenging when relying on manual efforts. This can lead to potential discrepancies and errors that can compromise product quality and brand image.

Time-Consuming Process

Manual labeling is inherently time-consuming, affecting production timelines and throughput. Handling large volumes of products manually slows down the entire production process, resulting in inefficiencies and bottlenecks. The need for frequent breaks, the physical limitations of workers, and the potential for human error all contribute to delays. This time-consuming nature limits the ability of businesses to scale their operations and meet growing market demands, ultimately affecting their competitiveness and ability to respond to market opportunities promptly.

The True Cost of Hand Labeling

You may be working with hand labeling and perhaps you have a couple of dedicated employees specifically assigned to applying labels for the hours they are working. Whether or not they are doing a good job, this could mean tens of thousands of dollars and hundreds of hours spent every year solely on labeling. Additionally, their productivity levels may vary from day to day and may lead to inaccuracies or slower speeds.

You also have to factor in that human workers take days off and vacations. They also may give their two-week notice. All of these factors may lead to a need for a replacement before you get too far behind, but you can not guarantee the accuracy, efficiency, or complete availability of the replacement either. It is important to note that making the switch does not endanger your current employees' jobs. With a labeling machine, your employees have more time to focus on other important and more satisfying tasks for your production.

Perhaps your concern is the affordability. If you cannot afford a large, high-output label applicator machine but want to make a switch from hand labeling, a tabletop labeler might be the solution for you. These portable labelers remove inconsistencies in label application and increase efficiency by 500%. They do not take up a lot of space either.  Even a small tabletop labeler like the ELF-20 is compact enough to fit on a workbench, but can still make labeling faster and more efficient. Plus, all of Pack Leader USA's label applicators are made from high-grade aluminum and stainless steel, which lasts for years.

The Inefficiencies and Limitations of Hand Labeling

Hand labeling not only introduces inefficiencies but also compromises the overall quality and aesthetic appeal of the final product. These drawbacks can have far-reaching effects on a business's reputation, customer satisfaction, and operational costs, ultimately impacting profitability.

Inconsistent Label Placement

Manual labeling often leads to inconsistencies, which can create aesthetic issues and affect the uniformity of the product presentation. Variability in label placement can result in crooked, misaligned, or improperly adhered labels, detracting from the professional appearance of the product and potentially damaging the brand's reputation. Such inconsistencies can also lead to issues with regulatory compliance if critical information is covered or rendered unreadable.

Increased Labor Costs

Relying on human labor for labeling significantly increases operational costs. The expenses associated with wages, training, and employee benefits add up, making manual labeling a costly endeavor. Additionally, manual labeling can lead to higher turnover rates due to the repetitive and strenuous nature of the work, which incurs further costs for recruiting and training new employees. Automated labeling solutions do require an initial investment but offer long-term cost savings by reducing the dependency on manual labor and minimizing labeling errors. These savings can then be reinvested into other business areas to help foster growth and innovation.

Compromised Label Quality

Product presentation and label quality are crucial in influencing consumer perception and trust. High-quality labels that are consistently applied enhance the visual appeal of products and reflect the brand's commitment to excellence and attention to detail. Consumers associate poorly labeled products with lower quality, which can destroy customer trust and loyalty. Labels that are crooked, wrinkled, or misaligned can give the impression of a rushed or careless production process. This not only affects the product's shelf appeal but can also result in practical issues, such as missing information or barcodes that cannot be scanned. Over time, these issues can accumulate, significantly affecting consumer perception and making it harder to build and maintain a loyal customer base.

The beauty of labeling machines is that they are able to grow with you and your business. This includes your design too. When hand-applying labels, the types of labels at your disposal are limited. Shrink sleeve labels are becoming increasingly popular and allow for eye-catching graphics that stretch over the entire container. However, these labels can not be applied by hand without specialized equipment.  Since they cover the entire product, the style options are limitless. They also do not require adhesive, are moisture resistant, and fit around oddly shaped containers. Shrink sleeve labels are known to be one of the most durable labeling options.  If your product would benefit from having beautiful full-sized graphics, stepping up to a shrink-sleeve labeler opens up a world of opportunities.

Pack Leader USA shrink sleeve labelers (SL Series) are designed for full-body sleeve labeling applications, neck and cap banding, and tamper-evident applications. Each option has varying size and labeling speed. The SL Series is well-suited for various industries and applications, including beverage, pharmaceutical, and cosmetics. Since they also have tamper-evident application capabilities and work on a wide variety of shapes and sizes, these applicators also work well on a wide range of compact pencils, lip glosses, and other tubes that are used exclusively for cosmetics products. This allows your customers to have an extra layer of security that their product has not been compromised, while other similar products may not offer them the same guarantee.

Scaling Challenges and Production Bottlenecks

Manual labeling processes present significant challenges when it comes to scaling production volumes. As demand increases, the limitations of manual labeling become more evident, with bottlenecks and delays hindering the ability to meet market growth. The reliance on human labor means that any increase in production requires a proportional increase in the workforce, which can be difficult to manage and sustain. Plus, the physical limitations of workers, like fatigue and performance, contribute to inconsistencies and slowdowns. Automated labeling solutions, on the other hand, offer the flexibility to scale operations efficiently, accommodating higher production volumes without compromising quality.

Streamline Your Labeling Process With Automation

While manual labeling processes rely heavily on human labor, automated labeling equipment offers a transformative solution. By reducing labor costs, minimizing errors, and increasing throughput, automated labeling solutions provide a favorable return on investment, making them essential for businesses aiming for long-term success in a competitive market.

Eliminate Human Error in Labeling

Your employees may be great and reliable workers, but no matter how accurate and consistent your employees might be, automated equipment will always be faster and more precise. This is especially true for wraparound labels for bottles, cans, or other cylindrical containers. While humans can be valuable employees, they also become fatigued, need breaks, take more time, or make human errors. Using a labeler can free up time, reduce employee fatigue, improve quality, and ensure all data is printed accurately.

Employees are also not always constant with other workers or even their own work. One issue you may face when applying labels by hand is peeling or bubbling due to application pressure variance. Unfortunately, any inconsistencies in application pressure can result in a poorly applied label that either has to be reapplied or thrown away, wasting time and resources. Semi-automatic and fully automatic labeling machines are made to apply even pressure to labels, making them adhere properly and look great every time. 
Speed Up Production
Your employees might have learned to apply labels quickly, but a labeler will always do it faster. Take tabletop labeling machines for example — a human can label anywhere between 300 to 500 labels per hour. In that same hour, a table-top labeling machine may be able to label up to 3,600 labels. Additionally, that equipment will not get tired or make mistakes. It will apply labels neatly and accurately from start to finish.  

In-line labeling machines are also adaptable to a wide range of labeling needs. They can increase output even more because they are designed to fit right into a packaging line. In some cases, an employee might have to remove containers from the line to apply labels before putting the product back for the next step of the production process. However,  an in-line labeling machine lets the product move through with no stops. This also reduces the time for labeling on multiple sides of the container and eliminates the opportunity for human error. Automatic labelers, like the Pack Leader USA PL-221D, can apply labels to multiple surfaces at once.

Customize Your Labeling Process

If you are looking for something to take care of your packing needs, even as they change, labeling machine applicators are a very customizable solution. For example, since Pack Leader USA’s labelers were built to be customized, they allow for wider conveyors, printers for date stamps or lot number placements, secondary label heads that minimize the need for adding new major equipment to your production line, and more. There are label applicator machines available for almost every label type and application need. There is something that caters to every different product type and size.

Boost Productivity and Enhance Operational Efficiency

Automated label applicator machines operate at high speeds, ensuring consistent and precise label application, which is often unattainable with manual labeling. By reducing the labeling cycle times, businesses can significantly enhance their throughput and overall operational efficiency. Automation eliminates the need for manual intervention, allowing employees to focus on more value-added tasks, such as quality control, process optimization, and other strategic initiatives. This shift increases productivity and enhances job satisfaction by reducing the repetitive and strenuous tasks associated with manual label applicators.

As production needs grow, the same automated equipment can handle increased volumes without the need for significant additional investments in labor or equipment. This adaptability is essential for businesses looking to expand their operations and improve their market presence. By adopting automated labeling solutions, companies can streamline their processes, enhance operational efficiency, and position themselves for long-term success in a competitive market.

Maximize Efficiency With High-Speed Automation

While manual labeling may seem cost-effective at first, the long-term costs associated with labor, errors, and inefficiencies quickly add up. Inconsistencies and errors in manual labeling can lead to wasted materials, rework, and potential product recalls, further increasing costs. Automated label applicator machines are a powerful tool that can significantly increase labeling speed, enabling employees to accomplish more in less time. These labelers operate continuously at high speeds, allowing your team to focus on other critical improvements in the production line without the burden of repetitive labeling tasks.

Automated systems can maximize your employee’s efficiency and productivity. The precision of these labelers reduces waste and ensures that each product meets quality standards, decreasing the risk of costly recalls or reworks. By integrating automation, you avoid additional costs while enhancing overall operational efficiency, making your workforce more effective and your production line more streamlined.

Overcome Manual Labeling Challenges With Automation

Manual label applicators come with significant challenges, including labor-intensive processes, inefficiencies, and increased operational costs. These drawbacks hinder operational efficiency, limit scalability, and compromise product quality and presentation. By adopting automated label applicator machines, businesses can overcome these challenges and achieve enhanced efficiency, productivity, and cost savings. Leveraging technology to optimize labeling processes is essential for supporting sustainable business growth in a competitive market.

Consider downloading our “Practical Guide to Choosing Labeling Equipment” to explore the benefits of automated labeling solutions and consult with experts for tailored advice on optimizing your labeling processes.

FAQ

Should I use an Automatic Label Applicator?

Automatic label applicators run much more quickly and efficiently than trying to label by hand. This prevents error, makes products more appealing, boosts sales, and saves a lot of time for your employees that can be redistributed towards other product needs.

What are Common Application Problems?

Some common issues that may be leading to your application problems include human error created during hand labeling, environmental issues, label conversion quality problems, container irregularities, labeling size, material issues, and using the wrong adhesive. 

What Types of Applicators Are There?

Different types of label applicators include manual labelers, semi-automatic labelers, and automatic labeling machines. Machine types can further be broken down into wrap-around labelers, top labelers, top and bottom labelers, front and back labelers, and shrink-sleeve labelers. The best machine for you may vary by product type, shape, size, and other labeling requirements. 

How do I Know Which Applicator to Choose?

The best way to determine which applicator will work best for you is to speak with a professional with experience in the field. Consider scheduling a free consultation with Pack Leader USA today or download the Choosing the Right Labeling Equipment Guide today for a more personalized labeling solution.