A shipping label can look perfectly acceptable to the human eye and still create problems once a parcel enters a carrier network. A barcode that will not scan, a label placed across a carton seam, or an old barcode left exposed can lead to manual handling, delays, relabelling or even misrouting.
A simple quality-control (QC) check before a package leaves the warehouse can prevent many of these issues. For high-volume fulfilment operations, these checks can also be incorporated into existing packing and dispatch processes rather than treated as a separate step.
Here are seven items fulfilment teams should verify.
1. Confirm barcode readability
Do not assume that a barcode is scannable simply because it printed correctly to the human eye. Wrinkles, streaks, faded areas, excessive darkness or missing bars can interfere with scanning.
Teams should periodically scan labels at the packing station, especially after changing label stock, printer settings or printheads. Incorporating verification into existing scanning processes can also help identify print-quality issues before affected parcels reach the dock.
2. Check printer calibration
Thermal printers can drift out of calibration, causing labels to feed incorrectly or print too high or low on the media. If barcodes, addresses or carrier markings begin shifting towards an edge, recalibrate the printer before continuing a production run.
A quick calibration check can help prevent a larger batch of labels from requiring reprinting.
3. Keep labels on a flat surface
Shipping labels should be applied to a broad, flat area of the carton whenever possible. Avoid placing a barcode over an edge, corner, seam, closure or highly textured surface.
Bending a barcode around a carton edge can distort its appearance and make reliable scanning more difficult as the parcel moves through automated handling systems.
4. Cover or remove obsolete barcodes
Reused cartons can contain old carrier labels, tracking barcodes, warehouse identifiers or product barcodes. Leaving these visible can create ambiguity for automated scanning systems.
Remove old shipping labels or completely cover obsolete codes before applying the new label. A final check should ensure that only the information relevant to the current shipment is clearly presented.
5. Match label construction to the environment
Direct-thermal labels are widely used for parcel shipping because they do not require a ribbon, but their printed image can be affected by prolonged exposure to heat, sunlight, abrasion and certain chemicals.
Warehouses should consider how labels will be stored and handled before shipment and whether packages are likely to face unusual environmental conditions during storage or transport.
6. Apply labels to clean, dry cartons
Even a strong adhesive can perform poorly when applied to dusty, damp, oily or very cold corrugated surfaces. Packers should quickly inspect the application area before attaching the label.
Pressing the entire label firmly against the carton can also help establish good initial adhesive contact and reduce the likelihood of edges lifting during handling.
7. Perform a final visual check
Before the parcel reaches the dock, confirm that the destination information is readable, the barcode is unobstructed, the label is fully adhered and no conflicting shipping labels remain visible.
High-volume operations can incorporate this check into an existing scan or pack-confirmation step rather than creating a separate process. Where checking every element manually is impractical, teams can also use routine verification to identify recurring printer, application or packing issues before they affect larger volumes of shipments.
Shipping-label quality control is a small operational discipline that can have an outsized effect. Most problems are relatively simple to correct at the packing station but can become considerably more disruptive after a parcel enters the carrier network.
A consistent seven-point check can help warehouses identify these issues while they are still easy to address, reducing avoidable handling and helping parcels move through the fulfilment process as intended.
The views and opinions expressed in this article are those of the author and do not necessarily reflect the views of Supply Chain Channel.
Mike Anderson
Mike Anderson is President of 4x6Labels.com, a U.S.-based supplier specialising in direct-thermal shipping and barcode labels for e-commerce, warehouse and fulfilment applications. He has more than 20 years of e-commerce experience and works with businesses on thermal-label formats, printer compatibility and high-volume shipping applications.
