When a parcel comes back to you, it's tempting to blame the courier, but a surprising share of returns trace back to something on the label. A wrong address, an unreadable barcode, a label that fell off, any of these sends a parcel back through no fault of the product inside. The frustrating part is that almost all of them are preventable with a little care at the bench.
The wrong or incomplete address
The most common cause of a returned parcel is an address that's wrong, incomplete or mis-formatted. A missing house number, a transposed postcode, a line that got cut off, any of these sends the parcel to the wrong place or back to you. Check the address against the order before you print, and if the customer's input looks odd, confirm it rather than assuming. Our address formatting guide covers the common fixes.
An unreadable barcode
The barcode is what routes the parcel, and if it's faint, smudged or scaled down, the parcel can't be sorted properly and gets held or returned. This is almost always a print quality issue, too little darkness or a label printed with 'fit to page' scaling, and it's fixed by printing at full size with enough darkness. Our barcode guide covers it in detail.
A label that fell off
Labels come off when the adhesive fails or the surface is wrong. A permanent-adhesive label on a clean, dry, flat surface stays put; a cheap label on a dusty or curved box peels off in the sorting machine. The fix is a proper permanent-adhesive label and a clean surface, which our adhesive guide explains.
The label over a seam or edge
Sticking a label across a box seam or wrapping it around an edge means it creases and tears as the box flexes, and a creased barcode doesn't scan. Place the label flat on a single panel, away from seams, edges and tape, and the barcode survives the journey intact.
Tape over the barcode
Covering the barcode with clear tape seems protective, but it reflects scanner light and can make the barcode unreadable. If you need to protect the label, use a label pouch or place it where it won't get damaged, but leave the barcode uncovered. This one habit prevents a surprising number of failed scans.
The wrong service or postage
A parcel sent on the wrong service, or with postage that doesn't match its weight or size, can be surcharged or returned. This traces back to estimating instead of weighing and measuring. Weigh every parcel, check the size band, and let the system quote from real numbers rather than a guess. Our surcharges guide covers what guessing costs.
Reusing or double-labelling
Reusing a box with an old label still on it, or applying a new label over an old one, confuses the scanners and can send the parcel to the wrong place. Peel or cover any old barcodes before applying the new label, and make sure only one barcode is visible on the outside of the parcel.
The five-second pre-dispatch check
Before a parcel leaves, run a quick mental checklist: address matches the order, barcode is dark and full-size, label is flat and not taped over, and there's no old label showing. It takes five seconds and catches almost every label mistake on this list, which is the cheapest quality control you'll ever do.
Frequently asked questions
What's the most common reason parcels get returned? An incorrect or incomplete address, followed closely by unreadable barcodes from poor print quality or scaling.
Should I tape over a shipping label barcode? No, clear tape reflects scanner light and can make the barcode unreadable. Leave it uncovered or use a label pouch.
How do I stop labels falling off parcels? Use a permanent-adhesive label on a clean, dry, flat surface, and avoid seams, edges and textured packaging.
The label that stays put and scans
Most of these mistakes are a label problem, and the fix is a good label. Our 100 × 150mm direct thermal labels stick fast and print a barcode that reads first time.
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