10 Common Mistakes to Avoid When Using Thermal Labels

Thermal labels are an integral part of various industries, from logistics to healthcare, where quick, reliable, and precise labelling is essential. However, improper usage of these labels can lead to inefficiencies, increased costs, and even operational disruptions. In this guide, we’ll explore the ten most common mistakes people make when using thermal labels and provide actionable tips to avoid them.

Choosing the Wrong Type of Thermal Label

Thermal labels come in two primary types: direct thermal and thermal transfer. Each type is suited for different applications, and selecting the wrong one can compromise the durability and functionality of your labels.

Common Mistakes:

1. Using Direct Thermal Labels for Long-Term Applications
   Direct thermal labels, while cost-effective, are sensitive to heat, light, and abrasion. They are ideal for short-term uses like shipping labels but unsuitable for applications that require longevity, such as product labelling for retail.
2. Overlooking Environmental Factors
   Ignoring storage and operational conditions can lead to faded or illegible labels. For instance, direct thermal labels should not be exposed to direct sunlight or extreme heat, as they can darken and lose readability.
3. Mismatching Label Material with Printer Type
   Using incompatible labels with your thermal printer can cause misprints, reduced print quality, and even printer damage. Always verify compatibility between the label stock and the printer specifications.

Solutions:

• Understand Your Requirements: Determine whether you need labels for short-term or long-term use. Opt for direct thermal for short-term applications and thermal transfer for labels that need durability.
• Consider Environmental Conditions: Evaluate the operating environment and choose labels that can withstand heat, moisture, or abrasion if needed.
• Match Printer and Labels: Consult your printer's specifications and purchase labels designed to work seamlessly with your device. Explore Label Power's thermal label range.

Improper Storage and Handling of Thermal Labels

Thermal labels are sensitive to environmental factors, and improper storage or handling can compromise their quality and performance. Ensuring the labels are stored correctly is critical to maintaining their effectiveness.

Common Mistakes:

1. Exposing Labels to Extreme Temperatures
   High heat or freezing conditions can warp or damage thermal labels, making them unsuitable for use. Labels stored in excessively humid environments may also lose their adhesive properties or become brittle.
2. Storing Labels Near Direct Sunlight or UV Sources
   Direct sunlight or UV exposure can prematurely age thermal labels, causing them to darken or fade before they are even used.
3. Failing to Keep Labels Clean
   Dust, dirt, and debris can accumulate on labels if not stored properly. This can lead to poor print quality or even damage to the printer head.
4. Stacking Labels Incorrectly
   Labels that are stacked improperly or subjected to weight pressure can become warped, making them difficult to feed through a printer and resulting in misaligned prints.

Solutions:

• Store in a Controlled Environment: Keep thermal labels in a cool, dry place with a temperature range between 20°C to 25°C and low humidity levels.
• Avoid Direct Sunlight: Use opaque storage containers to shield labels from UV exposure.
• Keep Labels Clean and Protected: Store labels in their original packaging until they are ready to be used, and ensure the storage area is free of dust and debris.
• Proper Stacking: Place rolls or sheets of labels flat, without applying excessive pressure on them, to prevent warping.

Ignoring Printer Maintenance and Calibration

Even the best-quality thermal labels can underperform if paired with a poorly maintained or improperly calibrated printer. Overlooking printer care can result in faded prints, misaligned labels, and increased equipment wear and tear.

Common Mistakes:

1. Skipping Regular Printer Cleaning
   Thermal printers accumulate dust, adhesive residue, and other debris on their print heads and rollers over time. This can lead to smudged or uneven prints and even damage the print head if not cleaned regularly.
2. Using Incorrect Printer Settings
   Misaligned settings, such as print speed and temperature, can cause poor-quality prints or damage the thermal label material. For example, a temperature that’s too high may cause the label to darken excessively, while one that’s too low may result in faint or incomplete prints.
3. Neglecting Print Head Alignment
   A misaligned print head can lead to uneven prints or improper placement of text and barcodes on the label.
4. Using Low-Quality or Worn-Out Printer Parts
   Using substandard or outdated printer components, such as rollers or ribbons, can affect print quality and shorten the lifespan of the printer.

Solutions:

• Clean the Printer Regularly: Use manufacturer-recommended cleaning kits to remove dust and adhesive build-up from the print head, rollers, and other components. Aim for a routine cleaning schedule based on usage volume.
• Calibrate Settings for Each Label Type: Adjust the print speed, heat settings, and label size within the printer’s software to ensure optimal results. For detailed instructions, consult your printer’s manual.
• Check and Align the Print Head: Periodically inspect the print head alignment and make adjustments as needed to ensure prints are centered and even.
• Use High-Quality Printer Supplies: Replace worn parts with manufacturer-approved components and avoid cutting corners with low-quality ribbons or rollers.

Overlooking Adhesive Properties and Label Application Techniques

The adhesive quality of thermal labels and how they are applied play a crucial role in ensuring the labels remain intact and legible throughout their intended use. Overlooking these factors can lead to labels peeling off, not adhering correctly, or becoming unreadable.

Common Mistakes:

1. Using the Wrong Adhesive for the Application
   Not all adhesives are created equal. Some are designed for temporary use, while others are permanent. Using a label with a weak adhesive on rough or moist surfaces can result in labels falling off prematurely.
2. Failing to Clean Surfaces Before Application
   Applying labels to dirty, oily, or uneven surfaces reduces their sticking power and longevity. Dust and debris can also prevent the label from adhering securely.
3. Applying Labels in Extreme Conditions
   Temperature plays a significant role in label adhesion. Labels applied in environments that are too cold or too hot may not bond effectively to the surface.
4. Using the Wrong Label Shape or Size
   A label that is too small or too large for the intended surface may not adhere evenly, increasing the chances of it peeling or falling off.

Solutions:

• Select the Right Adhesive: Choose adhesives based on the application. For instance, permanent adhesives are suitable for long-term labelling, while removable adhesives are ideal for temporary uses. For tough environments, consider labels with industrial-strength adhesive options.
• Prepare the Surface: Ensure the surface is clean, dry, and smooth before applying the label. Use cleaning agents, if necessary, to remove oils or debris.
• Apply Labels in Optimal Conditions: Check the temperature requirements for the labels and apply them in a controlled environment to ensure proper adhesion.
• Match the Label to the Surface: Use labels that are appropriately sized and shaped for the application to ensure maximum contact and sticking power.

Elevate Your Labeling Process with Best Practices

Avoiding these common mistakes when using thermal labels can save your business time, money, and frustration. By selecting the right labels, storing them properly, maintaining your printer, and ensuring optimal application techniques, you can achieve superior results and maximise the efficiency of your operations.

Ready to optimise your labelling process? Shop Label Power's high-quality thermal labels today!