Thermal-based barcode printers provide a very economical way to create high-quality labels, tags, wristbands, receipts, and tickets. Compared to other printing techniques, thermal-based options require less maintenance, have less expensive media, and print faster while maintaining excellent print quality.
Since these types of printers differ from your typical laser or inkjet printer, it can be a challenge to know which one will suit your business best. The first step in finding the right printer is to identify your specific need:
• Where will the printer be used? Is it a rugged environment?
• What kind of media will you make? Label, Tag, Wristband, Receipt or Ticket?
• How often will you print?
• Will the printer be in a fixed or mobile application?
Knowing how you are using the printer will help you decide which type, print method and other features you need. Understanding and going through the following features will help you determine the best printer for your needs.
Types of Barcode Printers
When finding the right printer, the first question determines what type of printing you are doing. Printers can be divided into 4 categories, depending on how mobile they are and if they can make labels, receipts, tickets, or wristbands.
Thermal Label Printers
They can be called “label” printers but these are by far the most flexible printers as they can print on any media that will fit inside the printer. If you are primarily making labels and you will also need to make tags or wristbands, then these printers are your all-in-one solution. However not all thermal label printers are the same.
The biggest difference between them is how heavy they can handle print volume. These printers come in many forms:
Desktop
This type of printer is made for small volume applications that are producing less than 500 labels per week on average. Desktop printers are perfect for property labeling in an office or for light printing duties at retail stores.
Printers such as the AirTrack DP-1 still produce the same quality and wider range of media than a small amount of large printers.
Industrial
Industrial printers are larger and more rugged than desktop models for high volume print applications. From two thousand labels per day to printing all day, these printers are designed to hold more media and have models that range from 5 to 8.
Supports printing up to. You will find printers such as AirTrack IP-1 at manufacturing and distribution centers as well as large retailers.
If you are printing any type of media in large quantities, industrial label printers are your most reliable option.
Mobile
Mobile printers are similar to thermal label printers, but provide freedom from any cable connection to the PC. Mobile printers have some limitations due to their small size. They are not made for very high volumes, have limited roll capacity, and are of small print width, typically 2 very, 3 very, or 4 or maximum. However, if you need to create a label or receipt on the move, a mobile printer will provide you with a high-quality print in a compact package that fits on your hip.
These printers are perfect for delivery drivers or sales agents who need to be labeled on the spot to receive in the field or to a warehouse worker.
Since these printers are not tied to a fixed PC, you normally communicate with them wirelessly via Bluetooth or Wi-Fi.
Move a mobile printer like the Zebra QLn320 to print on a laptop, mobile computer, or smartphone anywhere!
Wristband
Even though standard label printers can also make wristbands, a dedicated wristband printer offers many advantages and a lower overall cost. For every day wristband-making applications, like hospitals, theme parks and concert venues, a dedicated wristband printer is a perfect fit. While other printers have their own media on one roll, wristband printers have cartridges that keep you in print almost without downtime.
These printers also have a high print resolution standard for clear, accurate printing of images or logos. Paired with this, most models have a special anti-microbial case to meet the demands of any healthcare environment.
If you need regular custom printed wristbands, a dedicated wristband printer solution such as the Zebra HC100 will be the most efficient and easiest to use.
Ticket
Ticket printer is another special thermal printer that is excellent for printing on thick paper for ticketing applications. If you are making tickets for music festivals, festivals or any other type of event, a dedicated printer will help you make it faster with less hassle. Since most tickets come in a fan stack instead of a roll, these printers have a longer case to accommodate more stacked media. They can still use roll media but with a larger stack of stamps, you will spend less time reloading the printer.
These printers have an opening at the back of the case to easily feed the ticket stock to the exterior.
Models such as the Datamax-O’Neil M-4210 are a high-performance option for demanding ticket applications.
Print Method – Direct Thermal vs. Thermal Transfer
Once you know which type of thermal printer you need, the next major concern is which print method you will use. Thermal printers are capable of printing in 2 different ways – direct thermal (DT) and thermal transfer (TT).
Depending on how long you want the label to last and what material it is made of, one of the two methods will be more effective for your application.
Direct Thermal
Direct thermal printers use heat-sensitive media that pass under the printhead. Because they print without a ribbon, direct thermal printers are noted for their simplicity. Direct thermal printed labels typically have a considerable shelf life, but are not well suited to environments that expose them to heat, prolonged direct sunlight, or friction. Because of this, thermal labels, tags, or stamp stocks are often top coated to resist these elements.
Direct thermal printing produces sharp print quality with good scan capability using only one consumable.
For any short-term labeling application, direct shipping is the most efficient print method, like shipping labels
Thermal Transfer
Thermal transfer printers use a ribbon similar to a fax machine, which is melted onto the label by the printhead. This method makes it easier for outdoor and harsh environments to use label materials beyond paper, including synthetic materials such as polypropylene and polyester. In addition to the added durability, thermal transfer printed media have a very long shelf life for product labels, asset tags, and outdoor wristbands.
Since you are using a ribbon, you also have the option to change the color of your print beyond just black. With the right combination of labels and ribbons, you can create a label for any environment or application.
Although thermal transfer media costs a bit more to print, the added benefit ensures that your label or tag can be read for a lifetime without the need for reprint.
Barcode Printer Connectivity
Every printer should be able to communicate with some kind of computer that can get a print job for everything printed. Although it is possible to set some printers to standalone mode, you still need to connect the printer to a PC to set-up the first time. The majority of printing applications, however, will require continuous connectivity so that the printer knows what to print.
All fixed desktop and industrial printers will offer multiple options for connectivity, with USB being the most common today. Any PC or laptop today will have a USB connection and is one of the easiest to set-up. Just plug in the printer, install the driver on the PC, and you’ll be ready to print. Serial (RS-232) and parallel connection options are still available for most printers.
With network connectivity being a standard today, Ethernet and Wi-Fi options have become much more common in label printers. When your printer has an Ethernet connection, you simply connect to a network port and can now be accessed by any PC on a network as opposed to a USB-like case.
Some high-volume industrial printers, such as the AirTrack IP-1, now provide the standard with Ethernet connectivity, as it makes it readily available. When you don’t want to deal with cables, Wi-Fi on a printer makes it easy to put anywhere you like.
Since mobile printer design is a special case, wireless connectivity is a must. Most models provide a USB cable connection, but to get the benefit of mobility, Wi-Fi or Bluetooth will be used. Wi-Fi requires a wireless network to communicate like a fixed printer. The printer will work as long as you are within the network but for fully mobile applications, Bluetooth is a better option.
Bluetooth reduces your wireless range to 33 feet but works without a network because the 2 devices talk directly to each other.
Given that you are probably communicating to a mobile computer or tablet in your hands and the printer is on your hip, this is not a problem.
Integrated Add-Ons
After you reduce the type of printer and how you will print with it, the final step in finding the right printer determines which add-on accessories you may need. Many print applications may not require any of these options, but they may also be what makes a specific printer an indispensable tool for your business.
Most of these options are only available on desktop or industrial printers, although specific add-ons will differ from the model.
Cutter
A cutter does what his name is. As soon as the label is printed the cutter will separate the single label from the roll to which it is attached. Most label stock is already perforated so it is easy to tear off the printer but a cutter is essential when you are using continuous or specialized media.
Rewinder
A rewinder is an internal roller that allows you to print labels and feed them back to the printer on a new roll. This option is particularly useful for high volume applications that are printing large batches at a time.
With a rewinder you end up with a roll of printed labels opposite the stack of labels in front of your printer.
Peeler/Dispenser
This option takes each label as it is printed and separates it from the backing liner. Peelers are perfect for applications that are printing individual labels and then immediately applying them to a product.
This saves time by tearing off the label and then peeling it. However, if you print in batches this is not a good option as the printer stops printing until you remove it from the printer after peeling.
RFID
Some printers, including some mobile units, offer the option to create RFID-based labels. With this option, you can print the front of a label while encoding information in the RFID chip on the back of the label. The RFID option depends on which frequency range you are working on and most printers will support the UHF or HF range.
Creating RFID tags can be a challenge for those who are not very familiar with it. Talk to one of our RFID experts to ensure that you get the right printer for your RFID needs.
In-line Verifier
The in-line varifier is essentially a special type of scanner that extends toward the front of the printer. This scanner is analyzing each label that is made to ensure that it meets specific print quality requirements. If the printer is like Printronix ODV-2Dstarts to create labels below the grade you specify, the verifier will stop the printing process. When you are sending label products to major retailers or government / military locations, they will have strict rules on the print quality of the labels you make.
The penalty involved in not meeting their compliance is guaranteed to exceed the cost of the verifier.
Any business must seriously consider an in-line verifier for its printer to meet any type of print compliance so that fines and headaches of poorly printed labels can be easily avoided.
Finding the Right Printer
With all the options available for barcode printers today, it can be a challenge to find the right tool for your business. Determining the type of printing, overall volume, and what features you need from above will make it easier to decide on a printer.
If you are still having difficulty or have additional questions, feel free to call our experts – we are happy to help you find the right printer for your needs.