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Pre-printed barcode labels deliver zero pallet returns and a potential £100,000 saving for market leading UK logistics distribution company

Variable data labelling specialist AC Labels in Derby (UK) has completed the migration to pre printed barcode labels for a market leading logistics company.  The project delivered a major cost saving for the user from a reduction in rejected pallet movements due to barcode label errors to zero, as well as internal and external spend savings.


The logistics company was experiencing expensive problems with misrouted pallets as a result of poor quality barcodes printed on demand.  Using on site thermal label printers was quickly identified by Print Management partner GBF Print Management as being the cause of the errors and the bulk of the total cost, and a new solution using high quality pre-printed barcode labels proposed.


Once in use the high quality verified pre printed barcode labels ensuring pallet and lorry returns were eliminated. Labels were supplied on rolls in duplicate sets 2 across, thus ensuring that mis-identification of the pallets was significantly reduced. The warehouse operatives, who were previously spending 16 hours per week printing labels were now able to fulfil their primary roles increasing efficiency of the workforce within the warehouse. The use of pre-printed barcode labels eliminated the cost of a printer, thermal ribbon, blank labels and electricity running costs.


General Manager of AC Labels Peter Hartshorn commented “Whilst thermal label printing on site is required for some applications , there are many situations where it is an expensive and relatively low quality solution compared to having variable barcode labels pre-printed by an expert.  The detailed case study compiled for the information of our Print Management client base describing this project shows just how successful projects can be when both Print Management companies and us as manufacturers work together for the benefit of end users.”

The full case study is available as a White Paper download at