Why Labelling Machines Bounce: 9 Root Causes and How to Fix Them Properly
When a labelling machine underperforms, the symptoms are obvious: skewed labels, inconsistent placement, reduced speeds, frustrated operators, and rising reject rates. What is far less obvious — and far more important — is the root cause.
Across Australian manufacturing sites, labelling issues are often treated as isolated faults rather than system-level problems. Operators adjust guides, slow the line, replace rollers, or swap adhesives, only to find the problem returns weeks later. This cycle creates ongoing downtime, inefficiency, and lost confidence in the equipment.
At Impresstik, we approach labelling performance from an engineering perspective. In almost every case, the issue is not “the labeller”, but how the container, label, environment, and line configuration interact.
This article breaks down the nine most common root causes of labelling problems and explains how they should be fixed properly — not temporarily.
Symptoms vs causes: why fixes often fail
Before addressing specific issues, it’s important to distinguish between symptoms and causes.
Symptoms include:
labels skewing or drifting
wrinkles or air bubbles
labels lifting after application
inconsistent placement
reduced line speed
frequent operator intervention
Treating symptoms without identifying causes leads to repeated breakdowns. Proper fixes require understanding what is actually happening at the point of application.
Root cause 1: Container instability
One of the most common causes of labelling issues is container movement during application.
Lightweight PET bottles, flexible personal care packaging, and tall containers are especially prone to instability. Even slight movement during label contact can result in skew or misalignment.
Proper fix:
Engineering stabilisation into the system. This may include:
custom guides
wrap stations
side belts
top hold-downs
container-specific handling components
Slowing the line is not a fix — stabilisation is.
Root cause 2: Incorrect label size or placement
Labels that are too tall, too long, or positioned near bottle shoulders or bases are inherently unstable during application.
This often leads to:
wrinkling
edge lifting
inconsistent overlap
visible seams
Proper fix:
Review label dimensions in relation to:
container geometry
material rigidity
adhesive characteristics
application speed
Correcting label size often resolves issues without changing machinery.
Root cause 3: Mismatch between label material and application speed
Not all label stocks behave the same way. Some materials require more dwell time to adhere properly, especially at higher speeds or in cold environments.
Pushing speed without considering material behaviour leads to poor adhesion and inconsistent results.
Proper fix:
Align label material selection with:
speed targets
environment
container material
Engineering solutions may also include extended wrap or controlled application angles.
Root cause 4: Environmental conditions
Cold rooms, condensation, humidity, and washdown environments dramatically affect label performance.
Moisture interferes with adhesive activation and increases the risk of lifting edges or complete label failure.
Proper fix:
Design the labelling system for the environment by:
selecting appropriate adhesives
modifying application geometry
adding stabilisation
engineering moisture-tolerant handling
Ignoring environmental factors guarantees recurring problems.
Root cause 5: Inadequate integration with the production line
A labeller does not operate in isolation. Poor integration with upstream fillers or downstream equipment can cause inconsistent container spacing and speed fluctuations.
These inconsistencies directly affect label placement accuracy.
Proper fix:
Engineering proper line integration, including:
conveyor matching
speed synchronisation
spacing control
infeed and outfeed stability
Integration issues must be solved at the system level, not at the applicator alone.
Root cause 6: Excessive variation between SKUs
Running vastly different container sizes, shapes, and labels through the same setup without adjustment increases error rates.
Quick fixes often involve operators manually compensating for changes, which introduces variability and fatigue.
Proper fix:
Design changeover-friendly systems with:
repeatable settings
guided adjustments
modular components
This reduces reliance on operator judgement and improves consistency.
Root cause 7: Sensor and control limitations
Outdated or poorly positioned sensors can cause mistimed label release, especially at higher speeds.
This results in drifting placement, missed labels, or double application.
Proper fix:
Upgrade or reposition sensors and controls to match:
container characteristics
speed requirements
label feed behaviour
Modern control systems significantly improve repeatability.
Root cause 8: Worn or inappropriate components
Over time, wear on rollers, belts, guides, and peel plates reduces accuracy.
Temporary adjustments may hide the issue but do not restore original performance.
Proper fix:
Regular service and component inspection to:
identify wear early
replace parts proactively
recalibrate application geometry
Preventative maintenance is far more cost-effective than reactive fixes.
Service
https://www.impresstik.com/service
Root cause 9: Treating engineering problems as maintenance issues
Perhaps the most damaging mistake is assuming every issue can be solved through maintenance alone.
Some problems are design-related and require engineering changes, not servicing.
Proper fix:
Engage engineering review when:
issues persist despite servicing
production requirements change
new containers or labels are introduced
speeds increase
Understanding when to service versus redesign saves time and money.
Why engineering-led fixes outperform quick adjustments
Engineering-led solutions address the entire system:
container handling
label behaviour
machine configuration
integration
environment
This approach eliminates recurring faults and allows the labelling system to operate at its intended capacity.
Self-Adhesive Labelling Machinery
https://www.impresstik.com/labelling-machinery
When to service and when to upgrade
A simple rule of thumb:
If performance has gradually declined, service may be sufficient.
If issues appeared after a change in product, speed, or environment, engineering modification is likely required.
An honest assessment prevents wasted spend on ineffective fixes.
The takeaway
Labelling problems rarely have a single cause. They are almost always the result of multiple interacting factors that must be addressed together.
Proper fixes are engineered, not improvised.
Speak with our engineering team
If your labelling machine is slowing production or causing inconsistent results, our team can identify the true cause and recommend the correct solution — whether that’s service, optimisation, or redesign.
If your labelling station is slowing production, speak with our team and we’ll pinpoint the true cause and recommend the right fix.
Self-Adhesive Labelling Machinery
https://www.impresstik.com/labelling-machinery
Service
https://www.impresstik.com/service
Contact Us
https://www.impresstik.com/contact-us
