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Misaligned printing can be a real headache, especially in pharmaceutical packaging, where every label needs to be spot-on. If the print isn’t lining up right or labels are flagging, it can slow down production and cause compliance issues.
At Newman Labeling Systems, we’ve helped plenty of teams sort this out. The good news? Most of the time, you don’t need a full overhaul, just a few smart tweaks.
Fixing Misaligned Printing on Your Labeling Line
What Causes Misaligned Printing?
There are a bunch of reasons why printing might be off:
- Glue buildup on the conveyor or machine parts
- Web tension that’s too tight or too loose
- Worn-out rollers or misaligned label feeds
- Sensors that aren’t set quite right
- Switching between different label materials
- Old or worn stepper drives and couplings
Even something simple, like using a nearly empty label reel, can throw things off.
Quick Fixes That Actually Work
Here are a few things we’ve seen make a big difference:
- Clean the machine regularly – Dust and glue can mess with label placement.
- Adjust the tension – Labels should feed smoothly, not too tight or too slack.
- Move the product sensor – Shifting it slightly upstream can help labels apply more evenly.
- Stick to consistent label materials – Mixing paper and synthetic labels can cause problems.
- Check the motor and couplings – If they’re old or worn, they might need replacing.
- Use clear instructions – If you switch label types, make sure operators have step-by-step guides with photos.
Newman Tech-Tip: Slow Down to Speed Up
Sometimes, just slowing the line down a bit helps everything settle. Once things are running smoothly, you can ramp the speed back up. It’s a simple trick, but it works.
Why It Matters
Getting labels right isn’t just about making things look good, it’s about meeting regulations, keeping products traceable, and avoiding costly mistakes. A few small changes can save a lot of time and trouble.
If you’re still struggling, our team at Life Scientific, Inc. can help with virtual service troubleshooting or on-site support. We’ve seen it all and can get your line back on track quickly.
Need Expert Support? Contact us at 314-752-9400 to schedule a virtual troubleshooting session.
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