A thermal label is a shipping label created using thermal printing technology that applies heat to create images on special paper. These labels are the industry standard for shipping due to their durability, speed of printing, and low cost per label.
Types of Thermal Labels
Direct Thermal Labels
- Heat-sensitive paper
- No ribbon required
- Print head heats paper directly
- Image darkens where heated
Thermal Transfer Labels
- Requires ink ribbon
- Heat transfers ink to label
- More permanent print
- Better for harsh conditions
Comparison
| Feature |
Direct Thermal |
Thermal Transfer |
| Ribbon needed |
No |
Yes |
| Durability |
6-12 months |
Years |
| Heat/sun resistance |
Low |
High |
| Cost per label |
Lower |
Higher |
| Best for |
Shipping labels |
Asset tags, outdoor |
Common Thermal Label Sizes
Shipping Labels
| Size |
Use |
| 4" × 6" |
Standard shipping (UPS, FedEx, USPS) |
| 4" × 8" |
International, customs docs |
| 4" × 4" |
Returns, smaller packages |
Other Label Sizes
| Size |
Use |
| 2.25" × 1.25" |
Product labels |
| 3" × 1" |
Barcodes, SKUs |
| 4" × 2" |
Address labels |
| Various |
Custom applications |
Label Stock Types
Fanfold Labels
┌─────────┐
│ Label 1 │
├─────────┤
│ Label 2 │
├─────────┤
│ Label 3 │
└─────────┘
Stack format, feeds from back
Best for: High volume, desktop printers
Roll Labels
╭─────╮
╱ ○○○○○ ╲
│ Labels │
╲ ○○○○○ ╱
╰─────╯
Continuous roll
Best for: Industrial printers, very high volume
Thermal Label Materials
Paper Labels
- Most common for shipping
- Cost-effective
- Adequate durability
- Not waterproof
Synthetic Labels
- Polypropylene
- Polyester
- Waterproof/resistant
- More durable
- Higher cost
Specialty Labels
| Type |
Use Case |
| Weatherproof |
Outdoor exposure |
| Freezer |
Cold storage |
| Removable |
Temporary labeling |
| High-temp |
Industrial environments |
Buying Thermal Labels
Where to Buy
- Amazon
- ULINE
- Labelwriter.com
- Zebra (direct)
- Office supply stores
Cost Comparison
4" × 6" Direct Thermal Labels:
Brand name (Zebra): $0.04-0.06/label
Generic/compatible: $0.02-0.03/label
Bulk (5,000+): $0.015-0.025/label
Quantity Packaging
| Package |
Typical Count |
| Small |
250-500 labels |
| Medium |
1,000-2,000 labels |
| Large |
4,000-5,000 labels |
| Bulk |
10,000+ labels |
Label Compatibility
Printer Matching
- Check printer specifications
- Core size must match (1" vs 3")
- Width must fit (typically 4")
- Direct thermal vs. transfer
Common Compatibility
Rollo, DYMO, Brother, Zebra desktop:
→ 4" × 6" fanfold or rolls
→ Direct thermal
→ Most generic labels work
Industrial Zebra:
→ Roll format
→ 3" core typical
→ May need specific stock
Thermal Label Quality
Print Quality Factors
- Label stock quality
- Printer calibration
- Print head condition
- Print speed setting
- Darkness setting
Barcode Readability
- Critical for shipping
- Test with scanner
- Ensure adequate contrast
- Check for voids/streaks
Storing Thermal Labels
Best Practices
- Store in cool, dry place
- Away from direct sunlight
- Original packaging until use
- Use within 1-2 years
What Degrades Labels
| Factor |
Effect |
| Heat |
Premature darkening |
| Sunlight |
Fading, degradation |
| Humidity |
Adhesive issues |
| Time |
Reduced print quality |
Label Adhesive Types
Permanent Adhesive
- Standard for shipping
- Strong bond
- Difficult to remove
- Most common
Removable Adhesive
- Can peel off cleanly
- For temporary applications
- Returns processing
- Sample labeling
Aggressive Adhesive
- Extra strong
- Rough/cold surfaces
- Outdoor applications
- Corrugated boxes
Troubleshooting Label Issues
Common Problems
| Issue |
Cause |
Solution |
| Faded print |
Old labels, heat exposure |
Use fresh stock |
| Not feeding |
Wrong size, guides |
Adjust guides |
| Wrinkling |
Humid storage |
Store properly |
| Poor adhesion |
Dusty surface |
Clean surface |
| Blank areas |
Print head dirty |
Clean head |