In the food industry, “simple” adhesive labels are anything but simple.

Not only must food labels identify the product, its ingredients, and satisfy the U.S. Food and Drug Administration’s (FDA’s) “current Good Manufacturing Practices” (cGMPs), but also get attention, boost perceived value and close the sale. In addition, they must simplify inventory management, keep the unit price affordable and enhance quality and branding.

Since changing FDA regulations can render pre-printed labels “obsolete,” labels are often printed in small quantities to avoid wasted inventory. “Simple” labels must also stay legibly adhered, using the proper substrates, adhesives and inks, to safeguard the consumer and protect the manufacturer from liability.

Although labeling is admittedly the last thing a food or food equipment manufacturer considers when bringing a product to market, labels play a vital role in the industry. By following a few advanced label-printing tips, manufacturers can meet their sales, regulatory, quality and inventory management requirements more easily than ever.

Print On Demand for Labels
Perhaps the most significant development in label printing in the last decade is the introduction of print on demand (POD). Although widely adopted in recent years within the book publishing industry, POD has only recently established a foothold with label printers as the technology has been adapted for label printing, and more shops make the capital investment in the equipment.

POD label presses are full-color digital print systems that offer greater flexibility than conventional presses, specifically in terms of job setup and changeover times. For the food industry, POD printing of labels reduces lead times, improves supply chain management, equates to shorter run lengths and minimal stock holding and satisfies the requirements of variable data and other last minute changes.

“POD provides greater flexibility, faster turnaround time and the ability to make last second changes and adjustments,” says Barrie O’Brien, co-owner of American Label & Tag, a Canton, MI-based manufacturer of custom labels, tags, decals and nameplates that is now offering POD for labels. “For the food industry, the ability to quickly produce and receive custom labels is appealing when compared to the longer runs of labels using conventional label presses.”

Some pro-active food manufacturers are already taking advantage of label POD.

“To include a new line of chocolate covered confections in the Christmas catalog, we had to expedite label completion,” says Brian Jefferson, Chairman of Sanders Candy, a Clinton Township, MI-based maker of fine chocolate, candy and dessert toppings since 1875, and a division of Morley Brands, LLC. “With digital POD, American Label & Tag completed the labels for our line within two weeks for catalog inclusion.”

“We use POD to re-label product when we want to do a blowout sale or limited time offer for local or national retailers,” says Jefferson. “American Label & Tag helps make this possible with custom short runs of 1,000 to 3,000 labels with turnaround in a few days.”

Label Optimization
Some proactive food manufacturers are optimizing their process and profits by involving labeling expertise earlier in the product cycle.

“When we started a new line of chocolate covered confections, bringing in American Label & Tag from the design phase, to work with our internal creative team and outside design firm, helped us to save up to 33% on labeling,” says Jefferson. “Their input helped perfect the look, along with print sustainability, so labels look good time after time at a lower cost than we thought possible.”

Sometimes rebranding a product with a new label can create new opportunities and dramatically boost sales.

“When we re-labeled our chocolate melting drops for fondues and chocolate fountains, we tripled sales and gained entry to a major national retailer,” says Jefferson. The re-labeling was key to our rebranding effort, in changing perception from a bulk item to an upscale one, and American Label & Tag played a key role in that effort.”

Full material traceability, or back-tracking the supply chain and handling of all a product’s raw materials, can also help to prevent or limit potential recall if there’s ever a question of sub-par product, materials or processes. This protects both the manufacturer and the consumer.

Companies like American Label & Tag, for instance, can provide full material traceability for labels with a unique bar code system issued to all incoming raw materials from suppliers. The bar coding stays with the material in-house. Label bar code testing and verification also ensures that all are readable before shipment, which safeguards against potential returns to the manufacturer, says O’Brien.

One-stop Shop Capability
Despite POD’s potential, traditional label printing is still less expensive for longer production runs—if turnaround time is not an issue. Yet with limited lifespan, and frequent FDA changes, the clock is always ticking on food products, so to speak.

When turnaround time is of the essence, an expert “one-stop shop” label printer can eliminate bottlenecks and expedite delivery. By definition, a label printer that must outsource any aspect of the project automatically delays turnaround time. Outsourcing a die, for example, will add a week or two; not to mention opening the possibility that the die maker could be backlogged or fail to deliver as expected.

Instead, label printers that are vertically integrated, such as American Label & Tag, with all the capabilities from design and prototyping to die making and shipping, can turn jobs around much faster. With the addition of POD, turnaround time and the desired look has never been faster.

“When you’re dealing with thousands of labels that need to effectively sell your product, you can’t afford a surprise,” says Jefferson. “We prototype virtually all our labels to get just the right look before ramping up production.”

Getting the right labels to the manufacturing site is just part of the job, according to O’Brien. Companies like his work in partnership with the manufacturer to produce the right label, while keeping costs down.

“For cost efficiency, food manufacturers not only need to know how many labels are on a roll, but also how big the roll is, which way it’s oriented, and how it’s going on and coming off,” says O’Brien. “An effective labeling partner will look at all the factors, including consolidating or standardizing where possible to deliver the best product at the best price.”

Label Substrate and Adhesive Expertise
While food products are quickly consumed, food manufacturing equipment requires labeling that should remain legible and fade-resistant for years, especially when certifications are involved. Other labeling, such as that used in internal manufacturing processes, may be designed for easy removal or repositioning.

“For label substrate and glue/adhesive requirements that can vary widely, it’s best to work with a partner who can explore your needs and guide you to the best options,” says O’Brien, whose company has refined its label substrate and glue expertise by working with industry giants such as 3M for decades.

“For security in food manufacturing equipment, secure labels that read ‘void’ or fall apart when peeled up are available,” adds O’Brien. “For safety and economy in food products, simple paper, film or plastic substrates are a good place to start. A liquid UV coating can also provide a protective glossy coat that reduces smudging.”

Vendor Managed Inventory (VMI)
When food product lines may contain scores of products, each with different sizes, ingredients and labeling requirements, maintaining proper label inventory can be expensive and time consuming. In such cases, VMI—where the vendor holds the inventory and releases it to the manufacturer on an “as needed” basis—is worth considering. Similar to “just-in-time” manufacturing in the automotive industry, it reduces upfront inventory and handling expense, and can even enhance quality.

“We maximize our cash flow since American Label & Tag allows us to pay as we go,” explains Jefferson. “We preserve label integrity since they store our labels in a protected, climate controlled environment until we need them.” ♦

For more info, visit www.americanlabel.com; call 800.641.8247; Fax 734.454.7606; or write to American Label and Tag at P.O. Box 85488 Westland, MI 48185-0488.

Del Williams is a technical writer based in Torrance, CA.