Direct Thermal (DT) versus Thermal Transfer (TT)

Thermal transfer
labels and tags use a ribbon to create the image being printed. Heat from the print-head elements “transfer” the ink from the ribbon to the label.

Thermal transfer labels and tags are available in a wide variety of materials, from uncoated paper to high end synthetics. TT media can be used for virtually any application.

Direct thermal
labels and tags do not use a ribbon. Direct thermal media has a special top-coat that images via the heat from the print-head elements.

Direct thermal labels are commonly used for shorter durations than thermal transfer, and are not typically recommended for outdoor use.

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Die cut:
The most common type of label. Typically die cut labels have a .125" (1/8th) horizontal gap and .0625" (1/16th) margin edges on each side. Die cut labels and tags can be perforated, or "perfed", meaning the gap in between labels have a long series of holes making it easier to separate one label from the next. Since tags do not have a gap the perf is located at the end of each tag.

Butt cut:
Butt cut labels have no gap, and often have a sensor (black) mark for sensing. A vertical back (liner) slit or margin edges can be used to make removal easier.

Piggyback:
Refers to having 1 label on top of another. To make removing the top label easier the bottom label can be slightly larger than the top one, or there may be a vertical face (label) slit near the edge of the top label.

Barbell:
Most commonly used in the jewlery industry. The term "barbell" refers to the general look of the label. The 2 ends of the label are larger than the middle, or "bridge", causing them to look like a barbell.

Rattail:
Also used primarily in the jewelry industry. Rattail labels have a long, thin "tail" coming from the body of the label.

When using die cut labels a ribbon as wide as the "web" should be used. The web refers to the width of the label + the margin edges. Most labels have a .0625" (1/16th) margin edge on each side, which is normally stripped from the liner for ease of label removal. For example, 4" x 6" labels have a 4.125" web width.

Using a ribbon the width of the web promotes even printhead wear. Many ribbons have a backcoat to help prevent printhead damage.

Tags do not have margin edges so you can use a ribbon the width of the tag.

It's best not to use a ribbon much wider than the web width of the labels. Doing so may result in ribbon wrinkling.

To figure out how many ribbons are needed to print a specific number of labels you need to know the length of the ribbon (in feet) and the repeat (top of one label or tag to the top of the next label or tag).

For example: You want to print 250,000 4” x 6” labels with a Zebra 4.33” x 1,476' ribbon. Take the ribbon length in feet (1,476) x 12 (inches), then divide by 6.125 (Most die cut labels have a .125” [1/8”] gap, so the repeat is 6.125”). In this example you would take 1,476 x 12 (which equals 17,712 inches) and divide it by 6.125 (the repeat). Rounding down to the closest whole number, the correct answer is 2,891. So, each ribbon will produce 2,891 labels.

Then, take the number of labels to be printed (250,000) and divide by 2,891 (labels per ribbon). Using his example you would need 87 (rounded up from 86.47) ribbons to print 250,000 labels.