Picture this: You’ve just launched a new product. The marketing team is buzzing, sales projections look promising, and the shelves are fully stocked. But then, a minor typo in your packaging, a missing allergen claim, or a misplaced barcode brings the whole operation to a grinding halt. 

These errors are more common than you might think, and they can cost brands millions—not just in penalties, but in damaged reputations, lost customer trust, and expensive recalls.

Common packaging errors: What to watch out for

Here are some of the most frequent—and costly—errors that occur during packaging development:

• Typography mistakes: Misspelled words, incorrect fonts, or formatting issues.
• Barcode errors: Incorrect or unreadable barcodes that prevent products from being scanned at retail.
• Color inconsistencies: Mismatched colors between packaging batches, which can affect brand consistency.
• Regulatory non-compliance: Missing or incorrect allergen warnings, ingredient lists, or health claims.
• Mislabeling: Incorrect product names, descriptions, or nutritional information.
• Incorrect dimensions: Packaging that doesn’t fit the product or the required shipping containers.
• Image quality issues: Low-resolution images or pixelated graphics that affect print quality.
• Obsolete content: Outdated logos, claims, or promotional information that no longer apply.
• Lack of sustainability claims: Missing or incorrect recycling symbols or sustainability claims.
• Misaligned text and graphics: Poor alignment that makes the design look unprofessional.
• Missing or incorrect batch codes: Essential for traceability in case of recalls.
• Confusing design elements: Overly complex designs that confuse the customer or obscure important information.

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The real cost of packaging errors 

Packaging errors come in all shapes and sizes: 

1. Food industry: allergen mislabeling leading to costly recalls

Undeclared allergens are a leading cause of food recalls globally. According to the FDA, undeclared allergens and mislabeled ingredients accounted for 34% of food recalls and alerts in 2023. These recalls not only pose health risks to consumers but also result in substantial financial losses for companies. The average direct cost of a food recall is estimated at $10 million, excluding indirect costs such as brand damage and lost sales.

2. Cosmetics industry: non-compliance with allergen labeling regulations

In the European Union, regulations mandate the labeling of specific fragrance allergens in cosmetic products. Failure to comply can lead to significant fines and product recalls. For instance, in 2021, a Spanish company was fined €200,000 for selling cosmetic products that contained prohibited ingredients and lacked the required allergen information on the labels.

3. Beverage industry: misleading calorie information affecting consumer trust

Accurate nutritional labeling is crucial in the beverage industry. Misrepresentation can lead to consumer distrust and potential legal challenges. For example, Coca-Cola has faced criticism for its marketing practices that downplayed the health risks of sugary beverages, leading to lawsuits alleging deceptive labeling and advertising.

So, what’s the solution? 

Why manual checks just don’t cut it anymore 

As your brand scales across SKUs, regions, and languages, manual quality checks start to feel like trying to catch raindrops in a bucket. Here’s why: 

Human error is inevitable:

Humans are prone to mistakes, especially when performing repetitive, detail-oriented tasks. Even the most experienced quality control teams can miss small errors like incorrect font sizes, misplaced logos, or inconsistent color schemes. These seemingly minor mistakes can lead to massive financial losses, regulatory fines, and damaged brand reputation.

Inconsistent processes:

Without a standardized, automated approach, different teams may use varying checklists, guidelines, and standards, leading to inconsistencies. This fragmented approach often results in missed errors and conflicting feedback, slowing down the review process and increasing the risk of costly oversights.

Scalability struggles:

As brands expand into new markets and introduce more SKUs, the volume of packaging checks required multiplies rapidly. Managing hundreds or even thousands of SKUs across diverse regions, each with unique regulatory requirements, becomes impractical without significant manual resources.

Fatigue and oversight:

Repetitive tasks are not only exhausting but also prone to oversight. The more mundane and repetitive the work, the more likely critical errors are to slip through, as team members may become desensitized to the details over time.

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Why automation is the key to better packaging quality

Automation tools like Artwork Flow are changing the game for brands looking to eliminate these costly mistakes. Here’s how:

1. Automated text and barcode checks: 

Quickly validate critical elements like barcodes, ingredient lists, and regulatory claims to stay regulatory compliant and avoid costly recalls and fines.

2. Centralized collaboration: 

Bring internal and external stakeholders onto one platform for real-time reviews, feedback consolidation, and faster approvals.

3. Version control and audit trails: 

Maintain a single source of truth. Automatically track every revision, comment, and approval to eliminate confusion and compliance risks.

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4. AI-powered image and text matching: 

Use AI-led version comparison to review final artwork against previous iterations with three different comparison modes. The text comparison feature helps catch discrepancies at a glance.

5. Scalable and repeatable processes: 

Standardize your quality control with workflows that can be duplicated across teams, product lines, and regions. As your SKU count grows and you expand into new markets, you can apply consistent packaging checks without reinventing the process each time—ensuring accuracy, compliance, and speed at scale.

Proof in the numbers: How automation pays off

Brands using automated QA tools like Artwork Flow have reported: 

75% Increased efficiency:

Jones Dairy Farm improved operational efficiency by 75% using Artwork Flow. They also achieved a 400% boost in task management and a 50% increase in project completion rates.

60% Faster time to market:

LesserEvil cut its time to market by 60% using Artwork Flow, launching over 50 products with 50% fewer revisions.

“Now, everything is consolidated in one place. Our team has found the digital proofing tools intuitive and easy to use.”
– Manny Arthur, Design Manager at LesserEvil

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Final thoughts

In a world where first impressions matter, packaging errors are simply too costly to ignore. With tools like Artwork Flow, you can ditch the manual headaches and scale your brand confidently – no errors, no delays, just perfectly polished packaging every time.

Ready to transform your packaging process? Discover how Artwork Flow can help your brand eliminate errors, reduce costs, and enhance operational efficiency. Book a demo today!

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