Mar 14, 2025 by Matt Nichol
Manufacturers today face mounting pressure to do more with less – less waste, less energy, and less impact on the environment.
But are you looking in the right places?
Manufacturers often overlook coding and labelling processes as a source of significant waste. Every misprinted label, wasted drop of ink, or coding error adds up and impacts both your bottom line and progress towards your sustainability goals.
So, how do you stop the waste and streamline your processes?
Let’s explore five practical strategies to reduce waste in coding and labelling.
With Australia’s manufacturing sector producing nearly 13 million tonnes of waste annually, the urgency to tackle inefficiency is paramount. Beyond environmental concerns, waste in manufacturing impacts profit margins, slows productivity, and limits long-term growth.
The first step in tackling waste is understanding its source. Coding and labelling processes are prone to inefficiencies that can quickly spiral out of control. By identifying and addressing these issues, you can significantly improve your production line.
Here are the main culprits:
These inefficiencies don’t just affect production lines. They also have downstream effects, delaying deliveries and damaging your brand reputation.
Take mislabelled products, for example. When products are mislabelled or wrongly coded, entire production runs can be delayed. It can lead to expensive rework and scrapping of products and materials. If the shipment has already left for the customer before the error is discovered, this can also damage customer relationships and trust.
By tackling these issues proactively, you can streamline workflows, improve efficiencies and reduce waste. Reducing waste in coding and labelling can also contribute to your sustainability efforts. Efficient coding and labelling processes can lower material consumption and reduce wasted products.
Automation is a game-changer for reducing waste in coding and labelling. Automated systems significantly enhance efficiency by minimising human error, optimising material use, and ensuring consistent quality.
Take the manual application of pre-printed labels: an operator will likely make one mistake in every 300 touches. Scale that to thousands of products, and the risk of errors becomes unsustainable. A label printer applicator reduces this risk by applying labels with precision and consistency. It also boosts throughput, reduces bottlenecks (where humans cannot keep up), and frees up operators for higher-value tasks.
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Outdated equipment can be a hidden source of waste, from inefficient ink usage to outdated interfaces and menu flows that confuse operators. When machines are challenging to use, data entry or configuration errors are almost inevitable.
Upgrading to modern, user-friendly systems ensures operators can work efficiently and reduces the risk of mistakes. It also means the machine is running to its optimum and is less likely to break down or cause errors in printing.
Want to upgrade your carton coding equipment? Learn what to look for in a carton coder.
Manually entering data into multiple machines across production lines is time-consuming and error-prone. A centralised package code management system,such as Matthews iDSnet, eliminates this inefficiency.
iDSnet gives you a single source of truth for product information to create labels and codes, then manage label application or coding onto products. With iDSnet, all coding and labelling equipment – from printers to barcode scanners – is managed from one place.
When product information is updated in the central ERP system, it cascades automatically to the packaging line, ensuring accurate, synchronised coding every time. This eliminates the need for manual checks and data entry across machines, reduces the risk of errors, and saves valuable time. It’s all about the right information at the right time on the right product for the right packaging label.
Learn more about how package code management can reduce labelling errors and save costs.
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There are four stages of inspection you can use for product codes and labels:
Full vision inspection machines can catch mislabelled products before they leave the factory. These systems scan and verify every package, checking for label and code presence, positioning, and accuracy.
Vision systems and barcode validation systems can also ensure barcodes are present, readable, and accurate. They can match labels against other elements, such as verifying that front and back labels match on a product. Any detected issues trigger alerts, allowing operators to address problems immediately and minimise waste and downtime.
You can also use 2D codes to embed packaging variants, which helps ensure you are using the correct variant on the correct product. This method is often significantly cheaper than vision systems.
Find out how label inspection systems ensure zero defect labels.
Even the best systems need regular maintenance to perform optimally. Poorly maintained coding and labelling equipment can lead to misprints, illegible codes, or labels that don't scan.
Preventative maintenance programs help identify potential failures before they occur. Your equipment provider should offer a tailored plan to mitigate the top causes of machine failure. For example, Matthews Australasia’s Complete Care and Advanced Care programs include scheduled maintenance tasks to keep equipment running smoothly and avoid unplanned downtime.
It's just as important to maintain your IT infrastructure. Regular software updates and support ensure data accuracy, preventing costly errors in coding and labelling.
Understanding your coding and labelling processes is critical to identifying hidden sources of waste. Every misprint, misaligned label, or incorrect code represents an opportunity for improvement. By investing in the right technologies, automating your product identification, and maintaining your equipment, you can significantly reduce waste and create a more sustainable, efficient production line.
Contact us for more details about iDSnet and our other coding and labelling solutions. Our industry experts are on hand to discuss your needs and tailor a solution to suit your goals.