Solving Five Myths of On-Demand Color Labeling

Regulatory compliance, supply chain optimization and the development of a growing number of SKUs or customized products to meet varying demands of retailers and consumers are just a few of the labeling challenges facing today's industrial and consumer brand owners. On-demand color labeling is a cost-effective, efficient option to resolve many of these issues. However, the idea of switching from black and white printing, thermal transfer labels or pre-printed label stock can be daunting. The good news is it doesn't have to be. In this article, we’ll highlight some of the common misconceptions about on-demand color labeling and explore how the process can introduce greater efficiency, productivity and cost savings into manufacturing operations.

Myth No. 1: On-demand color labeling is not a good fit for my production needs.

Fact: Any manufacturer working with high-mix, low volume applications or needing to achieve compliance with regulations like GHS that have an impact on labeling can reap benefits from on-demand color labeling. At its core, on-demand labeling is about being able to print the number of labels you need right when you need them. Add color into the mix, and you have a labeling solution that is capable of quickly adapting to minor or major changes in branding, product ingredients, label design, or industry regulations. This adds up to savings in both time and money in the short- and long-term.

On-demand color labeling can also help manufacturers enhance their inventory management system. For example, the picking process can be simplified by using color coding or pictures on labels to differentiate products. Employees will be able identify the needed products or parts faster, creating additional savings and minimizing errors or delays that can result when the wrong item is pulled.

Myth No. 2: It will be hard to find a solution that will be compatible with my current software.

Fact: If you currently have a ZPL-based solution in your manufacturing line, a color printer that has a ZPL emulator will allow the printer to be plugged directly into your existing system and software work flow. Then, instead of using pre-printed color label stock, the color image can be loaded into the printer's memory. At run time, this color background will be merged with the monochrome ZPL data to produce a full color label on demand. This feature eliminates the need for pre-printed labels and the two-step printing process.

Myth No. 3: The long-term cost-savings that result from on-demand color labeling are not worth the start-up costs required to make the switch.

Fact: On-demand color labeling can help manufacturers reduce total label costs by up to 50% — meaning manufacturers will likely earn their investment in an on-demand label printer many times over. With on-demand color labeling, color and black and white information is printed all at once and labels are produced as needed — and in the precise quantities needed. This one-step process helps manufacturers decrease costs associated with labor and waste while also minimizing labeling and shipping errors and reducing the time needed to conduct changeovers. In addition, some on-demand color label printers, including Epson's ColorWorks C7500, feature individual ink cartridges for more efficient use of ink and a very low cost of maintenance. These printers are also designed with harsh commercial environments in mind. Many have industrial-strength outer shells for added durability and longer machine life.

Myth No. 4: Industrial on-demand color printers are just like color home desktop printers.

Fact: While there are certainly some similarities between the two technologies, there are some critical differences that are worth noting. For example, vastly higher capacity individual ink cartridges deliver much lower cost per label than typical home desktop printers. More importantly, these commercial printers are much more rugged in construction and are designed to handle orders of magnitude greater print volume than light duty home printers.

Myth No. 5: It doesn't matter what label media you choose for your application.

Fact: The media used by traditional two-step label printers is not always compatible with on-demand color printers. In fact, problems resulting from using incompatible media are among the top reasons why customers call Epson’s service and support team after making the switch to on-demand color labeling. It's worth noting that even though media has to have different properties than what is used for two-step printing processes, manufacturers have just as many options to choose from for their labels. On-demand color labeling compatible media options range from economical plain label stock to glossy, photo-quality paper labels. Keep in mind that depending on the end use of the label, manufacturers might need to use specific media to meet customer, industry or government requirements.

One way to avoid any incompatibility issues is to always purchase media from authorized labeling solution providers for the brand of printer you own. Using media from unauthorized suppliers can potentially reduce the quality of the print on the label and destruct readability, impacting brand recognition or leading to costly issues like product rejections.

Here’s the bottom line: manufacturers working with high-mix, low volume applications or needing to achieve compliance with industry or governmental regulations have nothing to fear about switching to on-demand color labeling. The technology is easy and cost-effective to adopt and delivers a multitude of benefits, including reduced total label cost, increased productivity and enhanced brand image.