5 Signs Your Labelling System Needs an Upgrade
Introduction
Labelling machines aren’t a “set-and-forget” investment. Over time, parts wear out, technology advances, and production demands evolve. Holding on to outdated equipment can drag down productivity and compromise quality. Here are five warning signs that your labelling system may need an upgrade.
1. Frequent Breakdowns and Downtime
Regular mechanical or electronic failures signal that key components are worn or obsolete. Each stoppage disrupts production, increases labour costs, and adds stress to your workforce. While basic repairs may keep an old machine limping along, the cumulative downtime often costs far more than investing in newer, more reliable equipment.
2. Slow or Manual Changeovers
If your team spends an hour (or more) adjusting guides, belt tension and sensor positions when switching products or labels, your system is inefficient. Modern labelling machines use quick-change parts, memory recall functions and touch-screen interfaces, allowing operators to switch sizes or shapes in minutes. Faster changeovers reduce downtime, increase flexibility, and enable smaller production runs.
3. Inconsistent Label Placement
Crooked, misaligned or wrinkled labels indicate that applicators, rollers or motors are not performing to specification. Variations cause brand issues, reduce shelf appeal, and may lead to rejection from retailers. New equipment features servo-driven motion and integrated sensors that adjust automatically, ensuring every label is perfectly positioned.
4. Growing Regulatory Pressure
Food and pharmaceutical regulations change frequently. Older equipment may not support the printing of variable data like batch numbers, expiry dates or allergen warnings at the point of application. Without these capabilities, you risk fines or product recalls. Upgraded systems incorporate print-and-apply modules, camera verification and traceability functions, helping ensure compliance with Australian standards.
5. Lack of Scalability
If you avoid taking on new customers or expanding your product line because your labelling capacity is maxed out, it’s time to upgrade. Adding shifts or manual labour can provide short-term relief, but modular machinery allows you to increase output sustainably. Choosing equipment designed for growth means you can add labelling heads, speed-up modules or other accessories as demand increases.
Benefits of Upgrading
Replacing an outdated system is an investment—one that quickly pays for itself. New machines operate faster and with greater accuracy, reducing labour costs and waste. They also come with local technical support, software updates and spare parts availability, ensuring minimal disruptions.
Practical Steps for Evaluating a New Machine
Assess current bottlenecks. Identify specific issues—downtime, misalignment, slow changeovers—and quantify their impact.
Research technology options. Explore modules and features that address your pain points, such as wrap-around heads, side applicators or integrated print units.
Engage a reputable supplier. Work with a company like Impresstik that can customise solutions, provide demonstrations and conduct site evaluations.
Plan installation and training. Schedule changeover with minimal disruption, and ensure operators receive comprehensive training to maximise benefits.
Budget for long-term value. Consider total cost of ownership rather than purchase price alone; factor in reliability, service, and the ability to expand.
Conclusion
An underperforming labelling system doesn’t just slow down production; it undermines your reputation and limits your ability to grow. Recognising the signs of ageing equipment early ensures you stay ahead of problems.
