They set a clear objective: consolidate label production, stabilize color and data, and keep changeovers tight as SKU counts grew. The brand partnered with onlinelabels for a rapid audit and pilot, aligning Digital Printing with their shipping stack and carrier rules.
The timeline mattered. Six months, three phased pilots, and a rollout plan that wouldn’t interrupt peak season. What follows is the step-by-step story, anchored by the numbers that guided each decision.
Company Overview and History
Founded in 2016, the retailer built its name on reliable next‑day delivery for household and personal care items across Southeast Asia. Labeling was initially a mix of Thermal Transfer and desktop Laser Printing—fast enough, but fragmented by site and device. As order volume rose, labelstock choices varied, templates drifted, and carrier scans became hit‑or‑miss.
Brand consistency pushed the change. Shipping labels are more than compliance; they’re an extension of the brand, from typography to tracking clarity. The team standardized on Labelstock compatible with Digital Printing and UV Ink for durable, smudge‑resistant output. They also updated templates to make room for variable data (GS1 barcodes and QR), while keeping space for notes and service icons common to custom shipping labels.
It wasn’t just technology. It was a workflow decision: centralize master templates, keep local autonomy on carrier selection, and move to On‑Demand production for short-run, multi‑SKU days. Early on, they learned that “fast” isn’t useful if color and data don’t land right the first time.
Quantitative Results and Metrics
Throughput changed by process rather than headline speed. On the main line, output moved from ~36k labels/hour (Laser/Thermal mix) to ~40–42k labels/hour with Digital Printing, depending on substrate. Changeovers now average 12–15 minutes versus the previous 25–30, especially when switching between standard formats and batches similar to 5160 labels layouts.
Color held steady. ΔE hovered within 2–3 for key brand marks across Labelstock and Glassine liners after G7 calibration. First Pass Yield (FPY) shifted from the 80–85% range to roughly 90–93%, with most misses tied to variable data mapping or carrier API timing rather than print quality.
Waste moved from ~9–10% to ~6–7% of lots on typical weeks. CO₂/pack measured 5–7% less than baseline due to fewer reprints and more precise lot sizing. These figures vary with promotion spikes and packaging mixes, so the team tracks ranges, not single-point targets.
Quick Q&A came up a lot during training: “does usps print labels?” For their U.S. exports, the answer was: USPS can generate and accept labels via third‑party platforms, but the team prints in‑house for control and compliance, guided by a parameter note shared on onlinelabels com. During the pilot, they used a small incentive—an internal code themed around onlinelabels $10 off—to encourage teams to consolidate orders into fewer, cleaner batches, making the data stress test more realistic.
Lessons Learned
Data beats assumptions. The turning point came when the brand mapped every label element—GS1, DataMatrix, and carrier fields—into a single master template library. Variable Data is unforgiving; one field misaligned and FPY drops. They built a rule set: lock typography, control whitespace, and define reserved zones for carrier requirements so scanning stays predictable.
There were trade‑offs. Digital Printing handled branding and consistency well, but thermal ribbons still had a role for certain rugged warehouse tags. Finishing mattered too: Varnishing and proper Die‑Cutting cut edge fray on heavy-duty liners, keeping scanner read rates healthy. The team kept a lane for custom shipping labels during promotional bursts and maintained templates that mirrored common 5160 labels grids for rapid training and cross‑site use.
Advice for others: set metrics before you set milestones. Track FPY%, ΔE, waste by lot, and changeover time. Designate one owner for brand consistency across all label types. Based on insights from onlinelabels’ work with multi‑site brands, consistency is the asset that scales. If you need a partner for template governance and substrate selection, revisit your plan with onlinelabels in mind.
