Reduce label material: the most underutilized optimization strategy in sustainable packaging
When it comes to sustainability in labels, most of the attention is focused on shifting to greener materials—recycled paper, PCR film, FSC-certified options. But there is a far simpler and more effective strategy that often goes overlooked: reducing label material right from the start. Using less material means fewer raw resources extracted, less manufacturing energy, less transport fuel, and less post-consumer waste—all of which directly contribute to lowering your carbon footprint, without requiring any changes to printing technology or your supply chain.
There are three primary approaches to material reduction that businesses can consider: optimizing label size, reducing or eliminating the release liner layer, and decreasing the number of layers in the label structure.
Three Feasible Ways to Reduce Label Materials for Real-World Production
1. Optimize label size: Many current labels are larger than necessary relative to the information they need to display, especially secondary labels, promotional labels, and logistics labels. Reducing label area by 10% can reduce material usage by 10% without compromising functionality. However, the optimized size must still meet requirements for barcode readability and mandatory information as per regulations.
2. Switch to linerless labels: The liner accounts for 30-40% of the material weight of a traditional label and is nearly impossible to recycle. Linerless labels eliminate this layer entirely, immediately reducing material usage by 30-40%. Best suited for logistics labels, shipping labels, and retail labels where aesthetics are not a top priority.
3. Reduce face material and adhesive layer thickness: Use thinner films (e.g., from 50 microns down to 38 microns) and reduce adhesive coat weight, provided durability and adhesion requirements are still met. Hirich can test thinner label constructions on customers’ own products to confirm performance before transitioning. In many cases, reducing film thickness by 20–25% has no significant impact on performance while delivering measurable sustainability benefits.
Hirich provides data-driven consultation to reduce label material usage
Reducing label materials isn’t a matter of blind cost-cutting. Every material reduction proposal must be evaluated against three key questions: (1) Will it affect performance on the labeling machine? (2) Will it compromise durability under real-world usage conditions? (3) Will it impact readability of information (barcodes, QR codes, small text)? Hirich conducts real-world testing on each proposed label structure, provides comparative data, and recommends the right optimization approach—helping businesses reduce material usage responsibly and with evidence-based confidence.
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