If you’ve ever had labels warp, peel, or slide right off bottles or jars after hot filling, you know how frustrating and costly that can be. We’ve seen it all, and we know what works (and what doesn’t). It’s always best to apply labels on a clean, dry, and room temperature container. But, sometimes it is necessary to hot fill.

Here’s what you need to know to keep your labels intact in hot-fill conditions.

Quick Checklist to Avoid Hot-Fill Label Failures:

• Select heat-resistant label materials (like BOPP or PET)
• Use adhesives specifically rated for high temperatures
• Make sure containers are clean, dry, and prepped right
• Choose label finishes that add durability (laminates, varnishes)
• Test label performance in real-world conditions before scaling up

Pick the Right Label Material

The first thing to get right is your label material. Not all of them handle heat the same way. We recommend:

• BOPP (Biaxially Oriented Polypropylene): Durable, heat-tolerant, and reliable. 
• PET (Polyester): Excellent heat resistance and dimensional stability.
• MDO: Similar to BOPP in terms of durability, heat tolerance, and reliability, MDO may be the better option depending on the container due to its flexibility.

Standard paper labels? Paper labels are possible for hot-fill products but be mindful of the type of adhesive used. 

Not sure which material makes sense for your product? Contact us and we’ll walk you through it.

Choose Heat-Resistant Adhesives

Your adhesive is just as important as your material (if not more). Without the right one, even the best label will fail. 

Most high-temp adhesives are rated for around 180–200°F, but results can vary depending on your container and fill speed. Always check the adhesive spec sheet and make sure it’s tested for your exact application.

Add Label Finishing for Extra Protection

Finishes help your label survive the journey from fill line to store shelf. They protect against scuffs, moisture, and the occasional warehouse disaster. Here’s what we like:

• Clear polypropylene or PET lamination: Great for moisture and abrasion resistance. Check out our lamination options.
• UV Varnishes: Good for extra durability without changing the feel too much.

Some finishes can change the look or feel a bit, so test them out before you commit.

Prep Your Containers the Right Way

Labels don’t stand a chance on a wet or dirty surface. And if you’re labeling plastics like polypropylene or HDPE, you’re starting with a tough surface to bond to. Here’s what helps:

• Dry the containers completely. Use air knives or drying tunnels.
• Wipe away oils, dust, or residue.

Prep won’t fix everything, but it goes a long way toward keeping your labels where they belong.

Apply Labels Under the Right Conditions

When it comes to applying labels after a hot fill, timing and pressure make all the difference:

• Temperature: Wait until containers cool to below 90°F before labeling.
• Pressure: Use consistent pressure so the label fully bonds.
• Dwell Time: Let the adhesive cure for at least 24–72 hours before handling or shipping. That gives it time to fully settle in, especially in humid or changing environments.

Running at scale? Run a small test batch first and check with your applicator manufacturer for pressure settings.

Validate and Test Before You Go All In

Even with the right setup, things can go sideways. That’s why testing is key. We suggest:

• Run a short trial batch.
• Mimic your exact fill and cooling process.
• Check your labels right away, then again after 24 and 72 hours.

Look for curling, peeling, bubbling, or anything that could get worse later. A little testing up front can save you a lot of headaches later.

Quick Summary

If you want labels that stay put after hot filling, you need the right combo of materials, adhesive, prep, and finishing.

Need help figuring it out? Contact us and we’ll help you find the right setup for your product, container, and process.