Thermal Barcode Printers: Explaining Media and Ribbons

Labels

What’s important to keep in mind is there is a media for every application, be that a simple shipping label that only needs to last 3 days, or a warning label that needs to last 10 years on the side of a fishing boat in the North Atlantic. Both are labels, and both can be printed using the same Thermal Barcode Printer, but each is specifically designed to meet the needs of a very different environment.

• Paper Labels
• Synthetic Labels
• Tags
• Specialty Media
  • Wrist Bands
  • Jewelry
  • Linerless

Paper Labels:
These are perfect for a wide range of applications such as shipping labels, labels on file folder and shelves, price tags, etc. or any application where the label does not need to stand up to the elements. Their chief advantage is price.

Synthetic Labels:
These labels are made of synthetic materials such as polypropylene and polyester (plastics). They are used in situations where the label will be exposed to an environment that is unfriendly to paper. While outdoor application come to mind (the side of the fishing boat), they also have some level of resistance to exposure to chemicals (think Health Care). How much exposure and which chemicals can very on the specific make-up of the label which is why there are such a wide variety of synthetic materials available.

Tags:
Tags tend to be thick paper without adhesive on the back. Garment and shelf tags are their most common application.

Specialty Media:
Labels and tags tend to be the most common media, but we need to mention at least a few of the most popular specialty Medias. Wrist bands are not only used in health care but also common in event management. Jewelry labels are all referred to barbell or butterfly labels because of their unique shape. They are used for wrapping around small items such as rings. Linerless labels are labels without backing materials. They use special adhesives and usually require a non-stock Thermal Printer with special non-stick label handling mechanisms.

Ribbons:

The label is only half of the media solution. For Thermal Transfer labels it is important to keep in mind the ribbon has to match the type of label you are using. When in doubt just ask whoever made the label which ribbon is appropriate but there are some general rules you can follow. The difference between ribbons boils down to the type of ink they carry. Different formulations of inks are used to adhere to different types of materials.

• Wax
• Wax/Resin
• Resin

Wax:
Wax ribbons are for use with paper labels.

Wax/Resin:
Wax/Resin ribbons are used with synthetic labels that have a matte finish. Also good for certain “coated paper labels” which are paper labels that contain a thin clear coating.

Resin:
Resin ribbons are used with synthetic labels that have a gloss finish. It is usually clear when the wrong ribbon is being used, as the ink will tend to either print very light, or the ink that does transfer will flake off easily.

Call us today to learn more on thermal printers : 1866-888-0303

Thermal Barcode Printers: A look at Printhead and DPI Requirements

In real simple terms a Thermal Printhead is made up of a series of perfectly square heating elements over a ceramic substrate. These heating elements are usually referred to as dots. The number of these dots per inch (dpi) indicate the resolution of the printhead. The standard DPIs are 203, 305, 406, 609. The higher the DPI the smaller each dot, hence a higher resolution. Matching the DPI to the application is almost as important as selecting the correct media. The next few slides detail when each DPI would be used. Outside of North America it is common to see the printhead referred to in Dots Per Millimeter.

• 203 dpi – 8 dot
• 305 dpi – 12 dot
• 406 dpi – 16 dot
• 609 dpi – 24 dot

203 dpi – 8 dot

One reason the DPI is so important is it dictates the size of the barcodes that can be printed. For most general barcoding and labeling purposes a 203 dpi printer is adequate. Each dot in a 203 DPI – 8 dot printhead is 5 mils wide. Each mil is .001 of an inch. This means the dot is .005 inches wide. Since you cannot turn on half a dot (it is all or nothing) the smallest barcode that can be generated is 5 mils. The size of the barcode then goes up in increment of 5. So a 203 dpi – 8 dot printer can generate barcodes of 5 mils, 10 mils, 15 mils, etc. For most general applications a 5 mil barcode is small enough. Most standard scanners usually have a minimum read spec of about 5 mils anyway. As you can see from the illustration below some basic graphics are printable with 203 DPI – 8 dot.

305 dpi – 12 dot

305 dpi – 12 dot printer have dots that are 3.3 mils wide. This allows for printing of barcodes of close to 3 mils. Since most high density scanners have a minimum read spec of 3 mils, 300 dpi – 12 dot printers are adequate for most customers high density barcode printing needs. 305 dpi – 12 dot also allows for more detailed graphics and smaller font sizes. It also allows for a range of barcode sizes that are not available using 203 – 8 dot, printheads, 3 mil, 6 mil, 9 mil, etc. It is important to keep in mind that if a customer’s barcode spec is very specific, which some compliant barcode specs can be, that a specific DPI printer may be required. For example if the customer has to product a 5 mil barcode, with no variation at all, they will have to go with a 203 – 8 dot printhead. A 300 DPI – 12 dot printhead just cannot produce a 5 mil barcode. Thankfully most customers do not have to be quite so specific. Most customers would have a hard time telling the difference between a 5 mil barcode printed with a 203 dpi – 8dot printer and a 6.6 mil barcode generated with a 305dpi – 12dot printer.

406/609 dpi – 16/24 dot

406 DPI – 16 dot and 609 DPI – 24 dot, are used for applications where extreme resolutions are needed. Often the need is for very detailed graphics or fonts. They both also offer a greater range of barcode mil sizes as well, useful if a specific size is required. They also allow for extremely small 2d barcodes.

Determining your DPI

DPI/MM and “X” Dimension

• How does this relate to a bar code?
• Remember the “X” Dimension?
• How would I print a 10 mil bar code?
• What about a 5 mil bar code?
• 12 mil?
• 50 mil?
• Mil Spec 1182 or 100% UPC?
• Graphics?
• Highest quality graphics or photos?

As we have seen the Dots Per Inch directly effects the size barcodes that can be generated. It also effects the quality of the graphics and fonts. Take a second and think about which DPI you would recommend for each application.

Printhead Widths

In addition to different resolutions, printheads (and the printers that contain them) come in different widths. This allows you to chose the width that is closest to the actual label size you are printing. By far the most popular width in label printers is 4 inches. There are other options which would be used for narrow or wide labels. The sizes listed here are just examples. With a print width of 5.04 inches, the Zebra 140XiIII+ for example, will fall between these sizes and the Sato M10e has a printhead that is 10.5 inches wide. It is important to remember there is a max label width and a max print width listed on printer spec sheets. Max label width indicates the actual width of the label and liner that can fit in the printer. Max print width indicates the actual width of the heating elements. For example the Datamax I-4210 has a max media width of 4.65 but a max print width of 4.10 inch. Using media wider than 4.1 inches will simply result in white space on the edges.

Tagged as: Education, Thermal Barcode Printer, training

Receipt Printer Technologies: Impact, Thermal and Inkjet

Impact:

Impact printing is done by several tiny pins, aligned in a column, striking an ink ribbon positioned between the pins and the paper, creating dots on the paper. Characters are composed of patterns of these dots by moving the printhead laterally across the page in very small increments.

The pins, contained in the printhead, are driven by several hammers (actuating plate) which force each pin into contact with the ink ribbon (and paper) at a certain time. The force on these hammers comes from the magnetic pull of small wire coils (solenoids/drive coil) which are energized at a particular time, depending on the character to be printed. Timing of the signals sent to the solenoids is programmed into the printer for each character, and translated from information sent by the host about which characters to print.

Benefits:

• Price – generally cheaper than other printing methods
• No special paper media
• Highly reliable and durable in harsh hospitality environments such as kitchens
• Impact receipts can be used with multi-part paper. This is ideal for credit card receipts and journaling

Drawbacks:

• Noisy – fine for a kitchen but not an upscale boutique
• Slower than other printing methods
• Ribbons that need replacing – ink on your hands

Thermal:

Thermal printing is done by a thermal print head that applies head directly to special thermal paper. When a specific temperature is applied the dyes and developers in the thermal paper chemically react and turn the paper the specific color of the dye.

Two color thermal printing is done similarly as well. Two-color thermal paper has two types (colors) of dyes and developers. At one specific temperature the first color (generally red, but can be other) is formed. At a higher temperature black is formed.

Benefits:

• Fast printing – Ideal for high volume retailers
• Quiet printing – when noise is unacceptable
• No ribbons to replace
• Two color printing on specific models

Drawbacks:

• Special thermal paper media
• More expensive than impact

Inkjet:

In thermal inkjet printing, the ink in a nozzle is heated with a small electrical element. As the ink heats to 300º Centigrade, it expands and boils to form a bubble. As the bubble grows, the ink is pushed out of the ink cartridge nozzle. When the bubble bursts, the droplet is expelled onto the paper. This technology is called thermal inkjet.

Benefits:

• Fast printing – Ideal for high volume retailers
• Quiet printing – when noise is unacceptable
• No ribbons to replace
• No special paper media
• Two/Multi color printing on specific models
• Receipts last a long time

Drawbacks:

• Price of purchasing spare replacement cartridges
• More expensive than impact
• Ink can smear

Changing the Command Language on an Intermec PC Series Printer

The Intermec PC series printers support several command languages, such as IPL or Direct Protocol. Changing the language on an LCD model printer is very easy to do.  Did you also know that it is easy to change the command language on an “Icon” version of the PC series printer, too?  This video shows exactly how it is done.