Common Shipping Label Problems and How to Fix Them
Troubleshoot common shipping label problems, including crooked printing, peeling, smudging, wrinkles, and barcodes that won’t scan.
Let the label experts help you troubleshoot
So you printed your shipping label, but something went wrong. Honestly, label fails happen to the best of us. Maybe it printed crooked, started peeling off, smudged, or won’t scan correctly. I’ve certainly dealt with these problems myself running my own small business. I’ve also learned a lot about preventing them since joining the Avery team. I mean, Avery has been making labels since R. Stanton Avery invented stickers in 1935. Nine decades of experience solving label fails and an R&D department onsite? I have access to literally some of the most knowledgeable label makers in the world.
In this guide, I’ll walk through some of the most common shipping label problems, what causes them, and what you can do to fix them—label expert-approved.
Why is my shipping label printing crooked or cut off?
Is your shipping label crooked or getting cut off when you print? Start by checking your printer settings and label size. The problem could be as simple as a mismatched setting, or you might be printing a postage format that doesn’t fit your labels. If everything looks right and you’re still having trouble, the label sheets themselves may not be feeding smoothly through your printer.
Printer settings are the first thing to troubleshoot
Before changing anything else, check your printer settings. Choose the “Label” setting in your printer preferences if it’s available. If not, try “Heavyweight,” “Cardstock,” or “Photo.” These settings adjust how your printer handles thicker materials like label sheets.
Still having trouble? Read our step-by-step instructions for choosing the best printer settings for labels.
Make sure your labels fit your postage
If part of your shipping label is getting cut off, make sure the labels you’re using are the right size for the postage you’re printing. When I first started shipping for my business, I didn’t realize that carriers and shipping services can have specific requirements for label size.
Many major carriers use a 4″ × 6″ shipping label format, including USPS and UPS. But, it’s always best to check the requirements for the specific carrier and service you’re using before printing. Then make sure your label size and print settings match.
Still printing crooked? Look at the label sheets
If your settings and sizes are correct but your labels are still printing crooked, the sheets may not be feeding smoothly through your printer. Choosing labels designed for reliable printer feeding can help. For example, Avery shipping labels with Sure Feed® technology have a unique “grip strip” that helps label sheets feed through printers better.
Why does my shipping label keep peeling off?
Stuck fiddling with a label that won’t stay stuck on? When a label starts peeling off, the adhesive is usually the culprit. You may be using a removable label, or a repositionable label that hasn’t had enough time to set…. or an old label that’s dried out. If the adhesive isn’t the problem, check the package itself. Dust, moisture, oil, wrinkles, and uneven surfaces can all prevent a label from making full contact.
Confirm that your label is meant to stay on
This might sound obvious, but make sure you’re actually using a permanent label. Removable labels are designed to come off cleanly, so they’re not a good choice when you need a shipping label to stay put throughout transit.
Repositionable shipping labels work a little differently. They’re designed so you can peel the label back and adjust it shortly after application. That’s really handy if you put your label on crooked—I definitely appreciate a second chance! However, the adhesive needs time to set and become permanent. If you’re using repositionable labels, follow the product instructions and give the adhesive enough time to set before shipping your package.
Make sure the label has full contact with the package
Even a strong permanent adhesive can’t do its job if something is getting between it and the package. Apply your shipping label to a clean, dry, flat surface where the adhesive can make full contact. Avoid dust, dirt, oil, moisture, seams, box openings, and wrinkles or folds on soft packaging. If the surface is uneven, find the flattest area possible rather than wrapping or bending the label around an edge.
Why not just tape over the shipping label?
You can use tape to help secure a shipping label, but I don’t recommend covering the entire label with it. Besides looking less professional, glossy tape can create glare over the barcode that may interfere with scanning.
If your label keeps peeling off, it’s better to figure out why it’s happening and fix the underlying problem. And if you’re worried about moisture during transit, consider using a waterproof shipping label instead.
Why does my shipping label smudge when I print it?
If your shipping label is smudging, start by checking whether your labels are compatible with your printer. Moisture can also cause problems during transit. And if you’re trying to print over labels that were professionally printed, the material or coating may not work with your home printer.
Match your labels to your printer
This is one I learned the hard way: laser and inkjet printers need compatible label materials. Match laser labels with laser printers and inkjet labels with inkjet printers. Using the wrong combination can lead to smeared or smudged printing.
Avery also makes shipping labels marked “Laser/Inkjet” that are designed to work with both types of printers. When you’re shopping for labels, you can filter Avery products by laser, inkjet, or Laser/Inkjet compatibility to help narrow down your options.
Consider weather during transit
Sometimes the label prints perfectly and smudges later. If your package may be exposed to moisture during transit, consider using waterproof shipping labels to help protect the printed information. I learned that lesson shipping holiday orders to snowy Colorado—yikes! I live in sunny southern California, so weather hadn’t even crossed my mind. But what the packages go through after they leave my hands really matters.
Don’t run professionally printed labels through your printer
I use both professionally printed and home-printed labels for my business, but I treat them differently. If you’ve ordered labels that were professionally printed, don’t assume you can run them through your home printer later. The label material may not be compatible with your printer, which can cause problems like smeared ink.
Pro tip: Professionally printed labels often have a special topcoat. Even if the underlying material is compatible with your printer, that coating can prevent additional ink from transferring properly.
Why won’t my shipping label barcode scan?
One of the most frustrating common shipping label problems is a barcode that won’t scan. Creases, folds, poor contrast, old shipping information, and even how you position the label can make a barcode harder for scanners to read.
Here are a few things to check:
- Keep the barcode flat. Apply your shipping label to a flat surface without creases or folds.
- Use plenty of contrast. Print with high-contrast ink on a light-colored label.
- Watch your placement on tubes. Always place barcodes lengthwise on tube packaging rather than wrapping them around the tube.
- Completely cover old labels and barcodes. If you’re reusing a box, make sure previous shipping information doesn’t show through. Labels with TrueBlock® technology are especially useful for covering what’s underneath.
But do wrinkles, folds, and glare really matter?
Yes. Barcode scanners “read” barcodes using reflected light. The light and dark areas of the barcode reflect that light differently, and that contrast is what makes the barcode readable by the scanner.
That also means anything that disrupts the direction or quality of the reflected light can cause problems. A barcode that’s bent, folded, or wrinkled can change how light reflects from it. Glare can also interfere with scanning, which is one reason I don’t recommend covering your entire shipping label with clear tape.
When you apply a shipping label, think about giving the barcode the clearest possible path to the scanner: keep it flat, visible, and free from anything that could interfere with how the scanner reads it.
Why does my shipping label keep wrinkling?
If your shipping label keeps wrinkling, the problem may be how you’re applying it, where you’re placing it, or the package itself. The good news is that a few small adjustments can help you get a smoother application.
Smooth the label down as you apply it
Instead of pressing the entire label onto the package at once, apply it gradually and smooth it down as you go. This helps the label make even contact with the surface and reduces the chance of wrinkles forming during application.
This is one of those things where a little technique goes a long way. Taking your time can help prevent air pockets and wrinkles before they start.
Find the flattest spot on your package
Seams, folds, edges, bumps, and other uneven areas make it harder for a flat label to lie smoothly. Choose the flattest area you can and avoid wrapping the label around corners or placing it across folds.
Keep flexible packaging in mind
Boxes give shipping labels a firm, stable surface, but flexible packaging can move. A poly mailer or soft shipping bag may bend or crumple after you’ve applied the label, causing the label to wrinkle along with it.
And wrinkles aren’t always just a cosmetic problem. If a wrinkle runs through the barcode, it can interfere with how the barcode scanner reads it. Keeping your label as flat and smooth as possible helps give the barcode a clear surface for scanning.
Fix the problem, then improve your workflow
Most common shipping label problems are easier to fix once you know what to look for. Whether it’s your printer settings, label material, adhesive, application, or barcode placement, a little troubleshooting can usually point you in the right direction.
Still have questions? Explore our online Help Center or contact our friendly Customer Care Team for expert guidance. They can help you work through the problem and figure out what to try next.
If you’re shipping regularly for your business, fixing individual problems is only part of the equation. I’ve also learned that having a good system makes the whole process easier. Check out the shipping label workflow I use for my own small business and what I wish I’d done differently from the start.
