Get Ahead of the Pack: Top 10 Reasons to Switch to Flexible Packaging

There are many exciting changes in the packaging world these days, but perhaps one of the biggest trends is the huge growth of the flexible packaging industry.  If flexible packaging did not exist, neither would bagged salads that stay fresh for days; frozen foods that steam right in their packages; household products like antibacterial wipes and easy-to-use laundry detergent; numerous health and beauty products; as well as single-serve protein and meal replacement supplements.

According to Flexible Packaging Association’s recent Flexible Packaging Transition Advantages Study, when given the choice between the same products in non-flexible packaging, 71% of consumers said they prefer flexible packaging.  In fact, this market is projected to grow from its current size of 102.19 Billion to 131.65 Billion by 2022.

There are numerous reasons why flexible packaging has become so popular, so here is our top ten:

  1. It’s lightweight, easy to store, carry and reseal
  2. Customizable – available in many different shapes, sizes and films
  3. Able to provide tamper-evident, reclosure and dispensing options
  4. Provides efficient product to package ratios
  5. Provides a smooth surface for high-quality printed images, so it’s visually appealing on store shelves and to consumers
  6. Less expensive to produce – although using plastic can appear cheaper, not as much material is needed to make flexible packaging. Some studies have put the potential savings from using flexible packaging at as much as 40%.
  7. Cheaper to Ship – the weight of a flexible material can be up to 70% lighter than that of traditional packaging.
  8. Able to extend the shelf life of many products, especially food.
  9. It is the ideal environmental choice because it uses fewer resources, generates fewer emissions and creates less waste
  10. It is at the forefront of important packaging trends in product protection, packaging design and performance.

In business since 1987, Overnight Labels has deep experience in the Flexible Packaging category.  Our presses are ideal for bags/pouches, stick/sample packs and sachets.  Our knowledgeable sales team can help you navigate the wide variety of substrates, inks and finishing options in order for you to make the switch, or to launch new product.

Seeing is believing…so order a Free Possibilities Kit to view our range of flexible packaging options for your brand.

To learn more, get in touch with us by calling 800-472-5753, or by emailing

CleanFlake Recyclable Adhesive

You’ve created a great product.  You want to be eco-friendly,   so you’ve chosen to use a PET bottle for its recyclability.  However, there is a catch. Pressure-sensitive labels typically limit PET recyclability into food-grade due to adhesive contamination.  In fact, 560 million PET bottles are wasted every year in the recycling process, largely due to incompatible label materials.

As a recipient of a numerous Sustainable Packaging and Environmental Excellence Awards, and as a member of the Sustainable Green Printing Partnership, Overnight Labels has been at the forefront of this movement for many years.  We are constantly on the lookout for the newest innovations in eco-friendly packaging.

That’s why we offer Avery Dennison’s CleanFlake™ , a water-based, recyclable adhesive that cleanly separates during the PET Plastic recycling process resulting in pure PET flakes, the conservation of virgin PET resources, and less landfill waste.

Check out this video demonstration to see how this product works:


To learn more, get in touch with us by calling 800-472-5753, or by emailing

Overnight Labels Is Featured In Packaging Technologies Today

A Look at Today’s Labeling Problems and Solutions

Labeling today faces different, and perhaps more complex, challenges than years past. Retailing issues, price point, and increasing competition on shelf lends the industry to look for more solutions to help ease the pain of labeling. So, what are the pains and how have these evolved over time?

We asked Don Earl, president of Overnight Labels, what CPGs want from labels today and how this demand changed over the years, and his response was surprising.

“Our primary business is in nutraceutical and beverage, and what we are noticing is that runs are getting shorter, companies have more SKUs, and we have less lead time. What’s interesting to see is that the more entrepreneurial companies want more innovation, and the less entrepreneurial companies want to create a simpler, less expensive label option. Big CPG brands are going to these types of labels, while small companies are coming onto the scene with beautiful labels to garner attention,” says Earl.

Why is that?

“When you start out as an entrepreneur, you want the effects, the beautiful labels, and then you enter large retailers and you need to lower cost, so design and labels have to alter for this. New brands can now skip the retailer and go straight to online sales. Traditional retailers are suffering and consumers are reporting a less-than-exemplary experience, with either items sold out, bad customer service, etc. It’s no surprise that more sales are going to online,” continues Earl.

How is the rise of digital printing affecting the industry?

“For one thing, it is accommodating the shorter runs. You can experiment a bit with digital printing. For big runs we still use the flexo, but for prototypes, digital printing works well, and quickly. The speed helps us show the prototypes quickly to our customers, which is important, because they face more competition within their industries, which means more products and formulas that need to be launched fast,” states Earl.

Labels aid in protecting the product inside, displaying pertinent information, and delivering great graphics. In general, why is the overall quality of labels so important?

As Earl states, “Quality is always important– we always operate with the idea that the label has to be perfect every single time, and every run.”

“We have water-resistant, light-blocking, and other labels, all ready to be tailored to the packaging need. In shrink sleeve, we see a lot of fresh beverages that use HPP (high pressure processing), which is a rough process for a label, so you have to use a specific label to hold up during the HPP process,” says Earl.

What challenges do your customers face as it pertains to labels? And what are the solutions?

“The biggest thing is speed to market, and reacting quickly. That is a struggle because there is more regulation than there used to be. Lead time is squandered in testing, legal, compliance review, ensuring all nutrition facts are accurate, etc. So then by the time that’s done, the customer needs it out asap. They promise a time to get the product on the shelf and compliance makes it difficult to meet that timing. Ideally, we would like 2-3 weeks lead time, depending on the complexity of a run, but with the changing landscape, we can do it in far less time, to help our customers out,” says Earl.


“To accommodate, we have to run efficiently and plan differently,” continues Earl.

Ok, so we know about the common problems of today, what are the trends you’re seeing?

“Years ago, people created a label that looked cool, now it’s all about creating a mood, and creating an identity with the brand. These companies are trying to create a bigger picture, not just one product, but a family of products with a brand behind it, and a rationale. And it all has to fit together. For instance, in the past, color coding was just out of convenience to signal which is which, now it’s used to create a whole brand picture, mood and vision. Also, now the product becomes part of the design; designers are getting savvier and leveraging the product to tie into the label.”

Established in 1987, Overnight Labels, Inc., is an award-winning U.S.-based manufacturer specializing in custom printed shrink sleeves, neckbands, flexible film, stick packs, booklets, peel-back and piggy-back labels, IRC coupons, confectionary wrappers, clamshell inserts, pressure and non-pressure sensitive labels, rotary silkscreen, foil, tactile varnishes, craft beer labels, embossed labels, reclosure labels, blister card backing, dual-chambered shrink sleeves, and more. Visit

2018 Packaging Trends

One day you’re in, and the next you’re out…..

A few years ago, masculine packaging was the next big thing…and now it’s all about minimalism and vintage.  As we kick off 2018, what trends are here to stay…at least for now?


Our client at Superieur Electrolytes is definitely on trend with their minimalist, organic packaging that gives consumers everything they need to know about the product – best tasting and better ingredients.  The look is achieved with a matte lamination on a standard gloss paper stock.


Shifa Tea provides soothing comfort, but our client’s on-trend foil packaging and brightly colored pressure sensitive label takes a flashier approach.  The look is achieved on a white BOPP (polybag friendly!) with a gloss varnish.  Now that’s what we call a great balance.


The hand-drawn look of Tickle Water’s adorable animals is just one element that makes the brand’s packaging special.  The unique, stand-out can is clear plastic with a clear label because for this all-natural sparkler, printed with cold foil on clear BOPP,  transparency is key.


The vintage lettering inspired by tattoo art adds to the authenticity of Devotion’s Nutritional Protein line. Since most protein powders on the market are typically a contemporary design with foil effects, Devotion’s playful shrink sleeve label makes it stand out in a crowd.

Does this packaging inspire you to make some changes?  We’d love to talk to you about how we can help!

Need samples? Request a Free Sample Kit

Have a question? Email us at or call us toll free at 800.472.5753


Don’t Be Fooled by the Name – The Shrink Sleeve Market Continues to Expand

You’ve got this great idea that you’ve spent countless hours nurturing into an actual product.   Now that you are almost ready to deliver it to the public, you want to make sure that the packaging on the outside is just as good as what’s on the inside.  With so many label options these days, how do you choose what’s right for your “Baby?”

Once considered the new kid in town, shrink sleeves are here to stay. This labeling technique that adheres film sleeves to products, offers many advantages including 360 degree visuals, product protection, conformity to the container shape, cost savings and the ability to bundle multiple products together.

Sounds like shrink sleeves are a great choice, right?  Well that’s true, but it’s important that you’re working with an experienced label professional when opting for this solution to avoid any packaging pitfalls. Consider these details before you press play on production:

Design Disasters

Despite their benefits, shrink sleeves have their own set of challenges when it comes to the design and manufacturing process. When bottles with dramatic curvatures and reliefs are being utilized, designers must have a clear understanding of how the artwork will distort. If the art isn’t up to spec and proofed properly, mistakes can happen.   You’ll want to choose a label manufacturer that approaches your project as a partner, not just a printer, as they will know if there are issues with the design.

“We will gladly size the container for you at no charge and will provide the specifications for your container. We will send you a layout noting any areas of concern (i.e. high shrink areas) as well as fold and seam positioning,” said Overnight Labels President Don Earl.

Material Missteps

There are several material types commonly used for shrink sleeve applications; the one that is correct for you depends on your budget, container shape, and interest in recyclability. For example, an extremely curvy bottle may require film with more aggressive shrink properties.

“Choosing the right material will ensure that the finished label shrinks properly and prevents imperfections in the finished label’s appearance, “It is imperative that you consult with your label printer and co-packer to recommend the type of film that is best suited for your product,” said Earl.

Solvent  Slip-ups

Don’t forget about your label’s seam! In addition to a good design, correct converting practices are a must to ensure accurate application of the solvent used to join the label seam.  Use of the wrong solvent can cause multiple problems that impact seams.  They can lift, causing a sharp edge or split, which could cause the sleeve to fall off.  An experienced label printer will guide you to make the right choice.

In business since 1987, Overnight Labels has deep experience in the Shrink Sleeve category.  In fact, we are one of the only printers in the country to use both matte varnish and foil on shrink sleeves, and in 2016 won a Bronze Leaf Award from the FSEA for this technique.

Seeing is believing…so  order a Free Possibilities Kit to see our range of Shrink Sleeve options for your brand.

Overnight Labels Is Featured In Packaging Strategies

Bottled lemonade shows off clean, simple label design

Overnight Labels produced these labels for Sweettauk

Sweettauk Lemonade was founded on the beach in the surf-mecca of Montauk as a brand that captures the sweet taste of summer in healthful, fun and fresh ways. The company began making organic lemonades at local farmers’ markets and soon opened a shop in its hometown of Montauk, NY. Now it has bottled up the goodness for everyone to enjoy anytime, anywhere – bringing its customers warm, feel-good vibes, all year long.

A clean simple form speaks to the pureness of the product. As a HPP (high-pressure pasteurized) product, Sweettauk was limited to certain types of bottle choices, finally choosing a stock “bullet” style PET bottle for its recyclability and communicated the brand’s message through label graphics. Overnight Labels offered a rotary silk screen white, which made the graphics on the label “pop.”

The company’s objective is to build the brand with a clear focus on “better for you” natural drinks, that have lasting social impact and prompt behavioral and cultural change.

Sweettauk balances sweet and tart, with no sugar added, nor any chemical-based sweeteners. Sweettauk is tart lemonade with 1 gram of sugar for the whole bottle.  A little organically grown, zero-calorie Stevia complements the fruit’s natural sweetness. Sweettauk Lemonade is available in a variety of flavors including Classic, Pink Hibiscus, Mango and Raspberry and sold at Whole Foods and other markets.


Packaging World – October 4, 2019

Overnight Labels Elevated to Platinum Level by GMI

Overnight Labels, Inc. has gone from Gold (previously called Blue) to Platinum Level status in its certification from Graphic Measures International (GMI).  This certification is a process that holds packaging suppliers accountable to established brand owner standards. GMI ensures brand integrity, ongoing production run sample measurement and in-store packaging assessments. Only 72 printers nationwide have achieved the Platinum designation, which is the highest available in the GMI ratings system.
Certification allows Overnight Labels inclusion on a network of printers who are approved to produce packaging for many retailer/CPG companies who utilize the GMI service, including CVS and Walgreens.  In order for certified packaging suppliers to achieve Platinum status they must meet the following criteria:
  • Combined pass rate/score from all GMI-SGS PQM programs is 95% or above, and
  • Yearly average pass rate/score is 95% or above for 36-months running, and
  • Total number of submissions is equal to or greater than 25 over the last 36 months

“Overnight Labels is proud of our new GMI Platinum level status because it recognizes the quality we strive to achieve every day, said Don Earl, President of Overnight Labels. “Whether a company requires a GMI printer or not, color consistency has always been an area of expertise for us. All of our customers are extra secure in knowing that we print to specific numbers and standards, not a subjective set of rules,” he added.