Reusable packaging labels are no longer the sticky problem they have been in the past. With label technologies continuing to evolve, be sure to talk to the pros and get solutions that work for your use case.
If you plan to pick up labels for your reusables at the local big box office supply store, that’s not a great idea, according to Dr. Shirl Handly, CEO of Norcross, GA-based FilmLOC. For everyday office printing needs rather than industrial labeling, specialized suppliers such as Supply Link USA offer a more practical source for ink and toner cartridges without the markup typical of big box retailers.
“The reason those won’t work is there’s not enough adhesive,” Handly explained. “The big box stores bid those out regularly, and the way you win the bid is having the cheapest paper with the least amount of adhesive on it. And that adhesive on those is not designed to stick to plastic or wood or metal or whatever. It’s designed to stick to paper. So it doesn’t need much adhesive.”
Choosing the right label for reusable packaging isn’t as simple as it might seem, and it is important to work with a knowledgeable supplier. Mark Molter, VP of Specialty Printing, a leading manufacturer of sustainable labeling solutions, compares it to selecting the right hammer for a job.
The Right Hammer
“You go to the hardware store, and there’s a hammer for each type of activity you’re doing,” he commented. “If you’re a roofer, you wouldn’t use a carpenter’s hammer. If you’re breaking up concrete, you wouldn’t use a finishing hammer. It is the same idea for labels. Having the right tool for the right job makes all the difference.”
Reusable packaging presents unique labeling challenges that require specialized solutions. Unlike disposable packaging, which requires labels to last only for a short duration, reusable packaging containers (RPCs) need labels that can withstand multiple handling cycles, washdowns, and environmental conditions and then come off cleanly when it is time for the next label.
In fresh produce, for example, temporary labels must survive the hydro-cooling process and stay intact, but then come off during the wash process after usage. Achieving this balance is a complex engineering problem.
The Label Sandwich
To truly understand the complexities of labels for reusable packaging, it helps to break them down into their core components. Molter uses the metaphor of a sandwich.
Each label consists of several layers, each with a distinct function:
- Topcoat: Determines printability, durability and resistance to water, chemicals, and extreme temperatures. Different varnishes can protect against moisture or abrasion, making them crucial for labels that must endure industrial wash cycles.
- Face Stock: The core of the label, typically made of paper or synthetic materials. Synthetics like polypropylene or polyethylene offer greater durability but come at a higher cost. Paper is less expensive and can be protected against moisture by the topcoat.
- Adhesive: Critical for performance. It must be strong enough to last through transport, handling, and refrigeration, yet release cleanly when required. Poorly designed adhesives lead to inefficiencies, particularly in RPC wash facilities, where labels that do not fully detach require manual removal.
- Release Liner: The backing material that supports the label until it is applied. Some companies are now exploring linerless labels, eliminating the release liner altogether to reduce waste and improve efficiency.
Stick and Release
Unlike labels for disposable packaging, which only need to function for a single trip, labels on RPCs must endure multiple handling cycles and environmental conditions. Standard adhesives that work well on cardboard boxes often fail when exposed to the rigors of reusable packaging.
Molter highlights this challenge. “You need a label that sticks through transport, but also a label that comes off cleanly at the washdown facility,” he said. “That’s the paradox we had to solve.”
A common issue in the produce industry illustrates this challenge. A grower in the field applies a label to an RPC in high heat and humidity. The label must then survive transport, refrigeration, and hydro-cooling. Later, when the RPC arrives at a wash facility, the label must release cleanly. If it doesn’t, workers have to scrape it off manually, leading to unnecessary labor costs and inefficiencies.
“The main challenge with labels applied to reusable packaging is the removal process,” agreed Aleksandra Wojciechowska, Regional Quality & Food Safety Manager at Tosca, a leading reusable packaging pooler. “Labels often leave behind paper fragments and adhesive residues, which aren’t always fully removed by jet washes and machine cleaning. Over time, this buildup results in complaints about asset quality and cleanliness.”
To mitigate this, Tosca provides customers with clear label application guidelines, including approved vendors, dedicated label zones, and specifications to ensure compatibility with their wash cycles.
FilmLOC’s Innovative Approach to Reusable Labels
FilmLOC, a leader in reusable label holders, has developed innovative solutions to address the persistent issue of removing stubborn labels from reusable totes and warehouse shelving. INTELLI-PLAC® label holders provide a durable surface for label application and easy removal, eliminating sticky residue and label buildup.
The company has also developed specialized products such as Cryo, a label holder designed for extreme sub-zero temperatures, and X2, an enhanced adhesive solution that ensures the label holders remain secure even through multiple wash cycles.
One common mistake Dr. Handly sees customers make when selecting labels is choosing a removable label to use in conjunction with INTELLI-PLAC, which can result in premature label release. “Some people think that if you have a placard, you need a removable adhesive to take it off,” she said, “but that’s not the case. You actually need a permanent adhesive.”
Additionally, FilmLOC has sourced BPA and BPS-free materials in response to growing concerns about food safety and certification requirements. “One of our suppliers just introduced a direct thermal coating that eliminates BPA and BPS, which is huge for the industry,” Handly stated.
Polyfuze’s Fusion Labeling Technology
Polyfuze Graphics has tackled the durability challenge of permanent labels on plastic reusable packaging by developing Polymer Fusion labels, which fuse directly into the plastic surface of reusable assets. “We don’t stick labels to plastic; we fuse them into the surface,” explained Marty Mares, VP of Branding & Commercial Development at Clarkdale, AZ-based Polyfuze. “This molecular bond ensures unmatched durability, guaranteed for the life of the asset.”
While permanent labels can become scuffed, difficult to read and even come off, Polyfuze labels remain visible and attractive for the life of the reusable. Mares also points out the importance of a solution like Polymer Fusion labels when it comes to maintaining the legibility of product safety information.
“Our Polymer Fusion Labels don’t just prevent label separation,” Mares said, “they eliminate the associated costs of operational disruptions, asset loss, re-labeling, and inefficiencies. By ensuring labels stay functional and intact, we preserve the integrity of data while enabling seamless integration with tracking systems, empowering companies to optimize workflows and achieve operational excellence.
In addition, Polyfuze’s RFusionID is an upcoming solution that combines RFID functionality with Polymer Fusion technology, ensuring permanent asset tracking without risk of label loss. “By addressing durability and data together, we’ve ensured that what’s attached to your asset stays with your asset—for life,” he said.
Specialty Printing’s LLC “Silver Bullet” Labels
Specialty Printing, LLC has developed a solution for lowering the costs and complexities found in labeling reusable packaging containers (RPC). This new and innovative product combines the durability required for labels to be used in wet environments, such as hydro-cooling, with the cost-effectiveness of paper labels and releasibility designed specifically for use in RPC wash plants.
“Labeling needs to be easier and more cost effective to help drive RPCs use and adoption” Molter stated. “This is a solution that lowers the cost of the labels initially to applier and helps reduce the cost of removal at the plants.”
The Shift to Linerless Labels
As sustainability becomes a greater focus, linerless labels are emerging as a viable alternative. Unlike traditional labels, which use a backing liner, linerless labels adhere to themselves. This eliminates liner waste and allows for more labels per roll, reducing downtime and costs.
Molter sees major potential in this technology: “Linerless labels offer significant advantages in warehouse and retail settings,” Molter said. “No more waste liner getting swept off the floor. Companies are seeing the benefits—lower costs, more labels per roll, and improved safety in plants by eliminating the slip hazard caused by discarded release liners.”
Another advantage of linerless labels is their precision in automated environments. Since they are applied using advanced machinery, they ensure uniform placement, which is crucial for automated scanning and logistics operations. Retailers with high-speed sorting and fulfillment systems rely on exact label placement, making automation-friendly solutions a key driver for linerless label adoption.
Regulations and Traceability
As governments tighten regulations regarding food safety and sustainability, traceability in reusable packaging has become more critical than ever. Initiatives like the Food Safety Modernization Act (FSMA) require manufacturers and retailers to track packaging and product movement throughout the supply chain.
“The Food Modernization Act really drove traceability into the food industry,” Molter commented. “Suddenly, everyone had to account for every ingredient—flour, sugar, eggs—down to the specific lot number. The same thing is happening in reusable packaging, where we have to track not just what’s inside, but where the packaging itself has beenthe contents were picked or packed.”
For industries such as fresh produce and meat, labeling is vital for meeting traceability mandates. The Produce Traceability Initiative (PTI) requires labels that capture farm-to-retail information, including harvest dates, grower identification, and batch numbers. This data must remain intact through extreme conditions like hydro-cooling, refrigeration, and washdown cycles.
Meat traceability has its own complexities. “The problem with early traceability efforts in meat and produce was inconsistency,” Molter said. “One supplier would call it a ‘packed on date,’ another called it a ‘born on date.’ Without standardization, tracking became a nightmare.” Today, labeling for reusable packaging used in meat and poultry produce handling must align with USDA and FDA guidelines, ensuring durability, scannability, and regulatory compliance.
Reusable packaging providers are now exploring smart label solutions—including RFID and IoT technologies—to make traceability easier while reducing reliance on disposable labels. With increasing regulatory scrutiny and consumer demand for transparency, companies that invest in robust labeling solutions today will be better positioned for the future.
Smart Labels: The Next Step in Intelligent Tracking
As reusable packaging continues to evolve, smart labels are becoming an essential tool for tracking and managing assets. These labels integrate technologies such as RFID (Radio Frequency Identification), QR codes, and IoT (Internet of Things) connectivity to provide real-time visibility in supply chains.
Dr. Handly notes the increasing demand for barcoded and QR-coded placards. “A lot of people are wanting some kind of embellishment, whether it be RFID, barcodes, or QR codes,” she noted.
At Polyfuze, the development of RFusionID eliminates durability issues associated with traditional RFID stickers. “We don’t stick labels to plastic; we fuse them into the surface,” said Mares.
Meanwhile, Tosca’s Asset IQ service uses RFID and IoT technologies to provide clients with accurate, real-time inventory data—without disposable labels.
Leading label suppliers continue to innovate, as reflected in the rise of BPA and BPS-free materials, placards, linerless labels, fusion labels, specialty adhesives and smart labels. At the end of the day, the right label isn’t just about durability or adhesion—it’s about solving a problem in the most efficient way possible. If a label improves tracking, reduces waste, and enhances overall supply chain operations, it is doing its job.
Contact the Vendors
For more information, reach out to label vendors and users featured in this article:
Related Articles
INTELLI-PLAC® Offers Scrape-Free Label Solution for Reusable Packaging, Racks and Shelves
RFusionID®, Merging RFID Technology with Polymer Fusion
Rick LeBlanc, EMBA, is the founder and editor of Reusable Packaging News (subscribe to the free newsletter) and editor of Western Pallet Magazine. A supply chain journalist with more than 30 years of experience, he specializes in pallets, reusable packaging, material handling and related operations. Rick is co-author of Pallets: A North American Perspective and Pallets & Progress: A Collected History of Pallets and Palletized Handling 1922–1945. He is also an advisory board member of the Virginia Tech Center for Packaging and Unit Load Design. Read Rick’s full bio.
