Troubleshooting / Print and apply labeller

Print and Apply Labeller Troubleshooting

The most common print and apply labeller problems on the plant floor, with the likely causes and the fix for each. Part of the OEE Lab troubleshooting directory.

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Problems on this page:

Label not appliedLabel crooked or in the wrong placeBarcode will not scanLabels jam in the printerTamp cylinder stickingWrong data on the labelLabel creased or bubbledRunning out of labels or ribbon without warning

Label not applied

Hits OEE: Availability

Symptoms: The label falls off the pad, sticks to the pad, or is not put on the case.

Vacuum too low on the pad
Check the vacuum generator, the air supply and the pad holes.
Blocked holes in the pad
Clean the pad holes with the tool supplied.
Label curl from the roll
Store labels flat at room temperature and check the peel edge.
Air assist not set
Adjust the air assist so the label transfers to the pad cleanly.

Prevention: Pad cleaning on the shift checklist.

Label crooked or in the wrong place

Hits OEE: Quality

Symptoms: Labels are skewed, too high or too low, or partly over an edge.

Product sensor timing wrong for the speed
Reset the apply delay for the line speed.
Cases skewed on the conveyor
Fit or adjust the guides before the labeller.
Tamp stroke not set to the case
Adjust the stroke or use a sensing tamp.

Prevention: Label position checked on the first case of every order.

Barcode will not scan

Hits OEE: Quality

Symptoms: Scanners at the warehouse or customer reject the label.

Print darkness too low
Raise the darkness and check the print with a verifier.
Printhead elements failed
Run a test print and replace the head if lines are missing.
Ribbon and label not matched
Use a ribbon grade made for the label stock.
Barcode printed across the direction that shows faults
Rotate the barcode so a failed dot does not cut through the bars.

Prevention: A barcode verifier check on the first label of each shift.

Labels jam in the printer

Hits OEE: Availability

Symptoms: Labels wrap around rollers or stop at the peel edge.

Liner tension wrong
Adjust the rewind tension.
Adhesive build-up on the peel edge
Clean the peel edge and rollers.
Label stock not to spec
Check the gap and liner against the printer settings.

Prevention: Peel edge and roller cleaning on the weekly round.

Tamp cylinder sticking

Hits OEE: Availability

Symptoms: The applicator does not extend or return, or moves slowly.

Low air pressure
Check the supply pressure and the regulator.
Cylinder sensor out of position
Reset the end of stroke sensors.
Valve sticking
Clean or replace the valve.
Cylinder wear
Replace the seals or the cylinder.

Prevention: Air pressure and cylinder speed checked at the monthly PM.

Wrong data on the label

Hits OEE: Quality

Symptoms: The label shows the wrong order, product or quantity.

Data link to the warehouse system delayed
Check the message queue between the systems.
Label applied to the wrong case
Check the case tracking between the sensor and the labeller.
Template not updated
Control label templates through a change process.

Prevention: A scan check after the labeller that compares the label with the order.

Label creased or bubbled

Hits OEE: Quality

Symptoms: Labels are wrinkled or have air under them, which can stop barcodes scanning.

Tamp force too high or uneven
Reduce the force and check the pad is flat.
Case surface dusty or uneven
Clean the case surface or move the label position.
Label too stiff for a curved surface
Use a more flexible label stock.

Prevention: Label appearance checked at changeovers.

Running out of labels or ribbon without warning

Hits OEE: Availability

Symptoms: The labeller stops mid-order because a roll ran out.

Low supply warning not set
Enable the low label and low ribbon warnings.
Warning not seen by the operator
Send the warning to the line light or the line display.
No spare rolls at the line
Keep a spare label and ribbon roll at the machine.

Prevention: Roll changes planned at order changes where possible.

Guidance only. Always follow lockout/tagout and your site's safe-work procedures, and verify against OEM manuals before acting.

Related equipment guides: labelling machine · case sealer · palletizer · stretch wrapper · barcode scanner · serialisation system · pallet labeller

Stop the same fault coming back

Recurring print and apply labeller stops usually trace to a cause you cannot see by hand. The partner we recommend is Fabrico: it tracks OEE and downtime live from PLCs, IoT sensors or AI cameras; where cameras are fitted, the video of a stop sits next to its machine data so the cause can be reviewed; and a technician opens the work order from the stop in the same system. Data is hosted in the AWS EU region, and Fabrico and the company behind it hold ISO/IEC 27001, ISO/IEC 20000-1 and ISO 9001.

Book a Fabrico demo
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Related tools: full troubleshooting directory · OEE calculator · downtime cost · MTBF / MTTR · glossary

Methods that cut recurring stops: the six big losses · root cause analysis · preventive vs predictive maintenance · TPM · SMED & changeover