40% Faster Peak Season Processing
A regional fulfilment centre transforms their shipping label operations ahead of Black Friday.
40%
Peak throughput increase
40%
Roll changes reduced
Eliminated
Slip hazards
Zero
Label-related downtime
The Challenge
Ahead of their busiest Q4 peak, this 50,000 sq ft fulfilment centre needed to increase throughput without adding staff or equipment. Traditional 4x6 shipping labels created bottlenecks: frequent roll changes, backing paper jamming in take-away systems, and cluttered packing stations.
The Solution
Converted 12 packing stations to linerless 102mm shipping labels. Each station equipped with Zebra ZD421 printers configured for linerless. Staff trained on the new consumables during pre-peak preparation weeks.
The Results
40% increase in labels printed per roll means fewer changeovers during peak. Elimination of backing paper cleared workstations and reduced slip hazards. Smooth Black Friday and Christmas peak with zero label-related downtime.
Pre-Peak Planning
Every fulfilment centre knows Q4 can make or break the year. This Midlands facility handles shipping for several e-commerce brands, with volumes tripling during Black Friday and Christmas. Previous years had seen bottlenecks at packing stations—not from the picking or packing itself, but from the labelling step. Roll changes during rush periods caused queues, and the constant flow of backing paper created cluttered stations and floor hazards.
The Linerless Solution
The operations manager had seen linerless labels at a trade show and decided to trial them ahead of peak. Starting in September, they converted 4 of their 12 packing stations to linerless. The results were immediate: 40% more labels per roll meant far fewer changeovers. With no backing to peel, labels went from printer to package faster. And critically, there was no backing paper piling up or slipping onto the floor.
Full Rollout Before Peak
By mid-October, all 12 stations were running linerless. Staff feedback was positive—the new format was actually easier than traditional labels once they got used to it. The warehouse safety team noted the elimination of backing paper on the floor, removing a slip hazard they'd been managing for years.
Peak Performance
Black Friday and the following Christmas peak ran smoother than any previous year. Zero label-related downtime. Packing stations stayed cleaner and safer. The 40% improvement in labels per roll meant the warehouse held less consumables stock while shipping more orders. Post-peak analysis showed the linerless conversion paid for itself within the first two weeks of November.
"We went into Black Friday expecting the usual chaos. Instead, our packing stations ran cleaner and faster than ever. The linerless switch was the best pre-peak decision we made."
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