Why Labels Fail: The Most Common Causes We See Label Failure (And How to Prevent It)

Label failure is rarely random.

In most cases, labels don’t fail because they’re poor quality, they fail because something about the application, environment, or handling wasn’t fully considered at the start. Often times, Romark is contacted to help businesses with these exact problems.

Over time, we've seen certain issues appear across different industries and production environments. Understanding why labels can fail is often the fastest way to make sure they don’t.

Below are the most common causes of label failure we encounter, and what typically prevents them.

1. Label Failure: Environmental Mismatch

One of the most frequent causes of label failure is a mismatch between the label specification and the environment it operates in.

This can include:

• Cold or freezer storage

• High temperatures

• Moisture or condensation

• UV exposure

• Contact with chemicals, oils, or cleaning agents
  

A common assumption is that if a label can survive an environment, it will apply correctly in it. In reality, sometimes application conditions matter just as much as operating conditions.

For example, adhesives behave very differently when applied to cold surfaces versus room-temperature ones. A label that performs well once bonded may never achieve proper adhesion if applied in the wrong conditions.

How this is usually prevented: Testing labels in real-world environments, including application temperature, before full production begins.

2. Surface and Adhesive Assumptions

“It sticks” is not the same as “it lasts”.

Another common issue is underestimating the surface the label is being applied to. Problems often arise with:

• Low surface energy plastics

• Textured or powder-coated materials

• Painted or treated surfaces

• Surfaces with residue, dust, or release agents
  

Adhesive strength alone doesn’t guarantee long-term performance. Compatibility between the adhesive and the surface is just as important.

In many cases, a label will appear secure initially, only to lift, edge-curl, or fail entirely over time.

How this is usually prevented: Matching adhesive types to the specific surface, and validating them through sample testing rather than assumptions.

3. Handling, Abrasion, and Human Interaction

Even when a label is applied correctly and suited to its environment, failure can occur later during handling.

This often includes:

• Manual handling during packing or assembly

• Contact with conveyors or guides

• Pallet movement and transport

• Repeated abrasion or scuffing

  
  

In these cases, the issue isn’t always the adhesive. It’s often the print durability.

Ink choice, print method, and over-lamination are sometimes treated as secondary considerations, but they play a major role in how well a label survives real-world use.

How this is usually prevented: Considering abrasion resistance and handling early, not after issues appear in transit or at the customer’s site.

4. Scaling Exposes Weak Specifications

A label that works well at low volume doesn’t always behave the same way at scale.

As production increases, small issues become much more visible:

• Faster application speeds

• Longer storage times

• Changes in packaging, transport, or storage

  
  

What was once an occasional failure can quickly turn into a widespread problem when volumes increase.

This is why label issues often surface during periods of growth rather than at initial rollout.

How this is usually prevented: Re-validating label specifications before scaling production, rather than assuming previous performance will automatically carry over.

5. Why Testing and Samples Matter

Most label failures are preventable.

In almost every case, issues can be traced back to early decisions made without enough real-world validation. Testing labels in the correct environment, on the correct surface, and under realistic handling conditions reduces risk significantly. Luckily, with Romark, we have decades of combined experience tackling all of these issues on a regular basis - so we get it right first time.

Sampling, when necessary, is about avoiding reworks, downtime, and unexpected costs later and if we think its important, we always recommend it.

Final Thoughts

Environment, surface, handling, and scale all play a role, and overlooking any one of them can cause issues further down the line. Understanding why labels fail is often the fastest way to make sure they don’t.

Our Commitment to You

At Romark Labels, we are committed to providing exceptional service and products and we understand the unique needs of each brand we work with. Our goal is to always help you find the perfect labelling solution that meets your specific requirements, while avoiding label failures and prolonging the long-life of your durable label.

If you’d like to discuss durable labelling for your own products, get in touch. You can also request a free sample pack to see the quality for yourself.

👉 Contact us today to request a free sample pack and see the difference industrial-grade labels can make.

Call us on 02033 846291 or email us at info@romark-labels.com to talk through your project.