The Secret of Affordable Bath & Body Labels

How small batch manufacturing taught me the secret to quality labels on a budget

I've been in the small batch manufacturing game for over 35 years, and in that time, I've literally gone through loads of printers. High end, low end— you name it. Currently our shop has half a dozen in-house printers, and there’s even more on the horizon. But if you're looking to outsource your labels, here's my experience.

It wasn’t always about having a machine humming away in the back room. There was a time when every label, every sticker, and every printed piece was a make-or-break moment for my brand. I experimented with everything from high-spec digital printers upwards of $10,000 to budget-friendly alternatives that sometimes left me with misaligned labels, faded hues and hours of frustration. Each printer came with its own set of pros and cons, and each taught me something valuable about quality control, turnaround times, and cost efficiency.

The Evolution of My Printing Process

Back in the early days, I believed that owning the entire production process was the hallmark of a true craftsman. I took pride in every detail, meticulously managing each printer like a prized possession. But as orders grew and the market became more competitive, I realized that in-house production had its limits. It wasn’t just about printing; it was about scaling your brand without compromising on quality.

Outsourcing became a strategic decision rather than a reluctant fallback. When you outsource, you're not just paying for printing—you’re investing in expertise. Specialized vendors come equipped with cutting-edge technology and a deep understanding of materials and finishes that many of us, no matter how passionate, just can’t match. This isn’t a sacrifice of quality for convenience; it’s a partnership that can elevate your entire brand.

My Outsourcing Revelation

I remember a specific moment when I had a huge order for eco-friendly, kraft labels for a subscription box. My in-house setup was fantastic for standard jobs, but the substrate was something new. I reached out to an outsourcing partner who specialized in sustainable printing. Their work not only met but exceeded my expectations. The labels arrived with impeccable detail, vibrant colors, and the environmental credentials that my brand promised. This experience was a game changer. It taught me that sometimes, the right partner can unlock a niche market while ensuring that your production process remains efficient and stress-free.

Here’s a tip from my years of trial and error: Always ask for samples. It might seem like a basic step, but receiving a tangible example of their work can save you from costly misprints and delays later on. Before I committed to any outsourcing partner, I requested a variety of paper types and finishes. It was an essential step that gave me the confidence to move forward and scale up production without hesitation.

Why Outsource Your Label Printing

I’m so lucky to work with some amazing beauty, bath & body, and candle brands—and let’s not forget the coolest fragrance companies on the planet. Many of these are scrappy startup brands, bootstrapping their way to big dreams. When funds are tight, a lot of my clients end up printing their own labels. But here’s the kicker: when you actually sit down and crunch the numbers—factoring in the cost of label material, toner, printer wear and tear, and the painstaking time spent printing labels sheet-by-sheet—you quickly see that professionally printed labels usually win on price. And quality? They’re always leagues ahead.

I’ve long since discovered the secret to affordable label printing, and I’m sharing a few tips that might get those pro-level labels into your hands sooner than you think.

Let’s break down some key terms that will not only make sense but might even get your toes tingling with excitement:

Digital Printing

This is the process where laser technology is used to apply ink directly to the label material. Unlike traditional printing, which relies on metal plates—and trust me, those plates aren’t cheap—digital printing lets you tweak your design on the fly. A single letter change or a small tweak doesn’t mean starting over with a new plate every time. For creative brands printing relatively small batches, digital printing is a total game changer.

Gang Run Printing

Ever heard of economies of scale? Gang run printing is all about combining several print jobs together on one professional printer. By pooling labels and placing one order, you can often reduce the cost-per-label dramatically. In other words, digital printing paired with gang run runs is often cheaper than what you can manage at home.

I personally recommend a couple of digital, gang-run printers: Lighting Labels, Wizard Labels and Sticker Mule. All three offer low minimum orders, free sample packs, a variety of label materials, online estimates, and quick turnaround times. Let me give you a quick rundown using Wizard Labels online estimator as an example:

• Scenario 1: I start with a single label design on white plastic (BOPP) with a gloss laminate finish, ordering just 100 pieces. The total cost comes out to around $164—that’s about $1.64 per label. Not a great deal.

• Scenario 2: Bumping that order up to 300 labels, the total cost rises, but the cost per label drops dramatically to roughly 56 cents each.

• Scenario 3: Pushing it further to 1,000 labels brings the price down to less than 20 cents per label—an 85% reduction compared to the 100-label run.

• Scenario 4: At 10,000 labels, you’re looking at an astonishing 4 cents per label!

As an entrepreneur and business strategist, there’s nothing more satisfying than watching economies of scale work their magic!

But What If You Don’t Need Thousands of Labels?

That’s where the beauty of digital gang-run printing shines. Say you run a gourmet cotton candy company like FluffPop. If you have, for instance, 25 different cotton candy varieties that all use the same packaging size—a clear tub, perhaps—you can design twenty five different labels that all share the same dimensions and material. Instead of ordering 100 labels for each variety separately, you combine them into a single 2500-label order. Boom—suddenly you’re hitting that sweet 20-cent-per-label price point. As your business grows, you can scale up each variety’s order, dropping the price even further.

Money Saving Label Strategies

1. Choose Digital Printing: For smaller orders, digital printing is your best friend. Sure, if you eventually hit tens of thousands of labels, traditional printing with metal plates might make sense financially. But for now, hit up Lighting Labels or Wizard Labels— they’ll even send you a free sample pack.
   

2. Streamline Your Packaging Styles: If your product line requires a myriad of label sizes due to different jars, boxes, or tubes, you lose the advantage of gang run printing. Consolidate where you can. Fewer unique sizes mean more cost savings.
   

3. Limit the Variety of Label Materials: Even when your label size is consistent, using multiple materials forces the printer to switch setups. Stick to as few materials as possible to tap into those gang run discounts.
   

4. Check Your Die Options Before Designing: A “die” is essentially the cutter that shapes your labels. Many good printers have a huge selection of dies available, and if you can use one of their standard sizes, you can avoid the extra cost of a custom die—which can run anywhere from $150 to $500. If you do require a die, ask the vendor for promo information. I've seen most run a promotion once or twice a year during slower periods.
   

5. Opt for PDF Proofs on Reorders: The first time you run a new label design, always go for a press proof—a physical sample to check colors, material fit, and durability. It might cost a bit extra with shipping fees. But once you’ve got the design dialed in, switch to PDF proofs for subsequent orders. It saves time and money since you already know the physical details are spot-on.
   

6. Proofread to Avoid Costly Mistakes: Proofread your labels multiple times, and have friends or family double-check them too. I still cringe when I think about the time I printed 3,000 “tanning mouse” labels instead of “tanning mousse.” Trust me, a little extra caution goes a long way. Also, cut out a paper template of your label’s size and tape it to your packaging to ensure a perfect fit before committing to a full run.
   

7. Plan for Delays: Order your labels well before you need them. Production issues and shipping delays are inevitable, and nothing is worse than a looming deadline with your labels still in transit. Build in plenty of lead time—and then add an extra week as a safety net. Trust me, you don’t want to face the nightmare of having to pay an extra $100 to overnight a $200 label order. I’ve been there (more than once), and it’s a costly mistake that's easily avoided.

The Upside of Outsourcing

Outsourcing your labels offers flexibility. Instead of being locked into one technology or process, you have the freedom to choose the best option for each project. Need a quick run for a seasonal promotion? Outsource it. Launching a new product line with intricate design details? There’s a specialist out there ready to help. This flexibility means that you can focus more on your creative process and less on the technical challenges of printing.

Moreover, outsourcing can free up precious time. Instead of micromanaging every detail in your studio, you can channel your energy into growing your business and perfecting your craft. In today’s fast-paced market, that edge can be the difference between staying afloat and truly thriving.

So, if you’re a handmade seller wondering whether to stick with in-house printing or to explore outsourcing, remember this: Your time and energy are valuable. Trust your instincts, do your homework, and consider that sometimes, stepping away from the printer can lead to the best prints of all. Embrace the change and let your labels tell your brand’s story—loud and clear.

First impressions matter—especially for creative brands. A smartly designed, professionally printed label isn’t just a sticker; it’s a powerful piece of your brand story. So, if you’re ready to level up your packaging game without breaking the bank, consider these strategies. I’d love to hear your favorite label printer or any tips you’ve picked up along the way—drop a comment below!