Understanding Thermal Labels: Direct Thermal vs. Thermal Transfer (2024)

Among the most commonly used labels bybusinesses across the world are thermal labels, including direct thermal andthermal transfer labels. Thermal labels are those that are printed usingthermal printing technology, using heat to print the desired pattern on labelstock. Compared to traditional printers that use laser, inkjet or dot matrixtechnologies, thermal printers are more reliable, fast, and cost-effective forprinting labels.

Having an in-house labelling system offersimmense benefits and opportunities for cost savings, especially if yourbusiness deals with a large volume of products. If you require customised andon-demand labels, then a labelling system is a must have. For an adequatelabelling setup, all you need is a pos software or labelling software, labelprinter and label consumables such as label rolls, and ribbons if applicable. Aone-time investment in the label printer will last you for years, and you canexperiment with different kinds of label rolls depending upon your labelling requirements.

Thermal labels are fast to print, have reducedprinting costs, and produce goodquality labels. Even though direct thermal and thermal transfer labels bothuse heat to produce the designs, there are significant differences between thetwo. The biggest differences are in terms of printing quality, durability, andcosts. While direct thermal labels are more suitable for short to medium lifespan applications, thermal transfer labels have a longer shelf life.

Here is a comprehensive comparison of directthermal and thermal transfer labels, so that you can choose the right type oflabels for your business needs.

What are Thermal Labels?

In general, thermal labels are any kind oflabels that have a design created using heat. Thermal printers are fast, quietand cost-effective, making them ideal for printing low cost labels in bulk,while still supporting customisation. Since thermal printers are lightweight ascompared to other printers and smaller in size, they are portable and can besetup wherever the need arises. They also consume less power, adding to theircost-efficiency.

Thermal labels have plenty of applications,including product labels, barcodes, ingredients, dates, food labels, pricetags, pharmaceutical labels, and shipping labels. Thermal labels can easily beproduced in bulk, making them ideal for a variety of industries such as retail,grocery shops, convenience stores, and eCommerce.

There are two types of thermal labels, namely,direct thermal labels and thermal transfer labels, based on the printertechnology used for printing the label.

1. Direct Thermal Labels

Directthermal labels are printed by direct thermal printers that use specialisedheat sensitive paper and a heated print head to transfer the desired pattern.There is no need for any additional ink, ribbon or toner, since the pattern isprinted on chemically treated paper using heat. Despite the costs ofspecialised heat sensitive label stock, the overall printing costs are low.However, since the label material is heat sensitive, it has low durability anda short life span. Direct thermal labels are typically printed in black, or atthe maximum support two colours, and are easy to print. These printers aregenerally compact and well-suited for environments where space is a constraint.

Advantages:

Simpleto print
Costeffective
Suitablefor bulk printing
Highclarity labels suitable for barcodes
Canbe printed on paper and synthetic materials

Disadvantages:

Shortshelf-life
Exposureto heat and abrasion can damage the labels
Cannothave multiple colours

2. Thermal Transfer Labels

Thermaltransfer labels are printed using thermal transfer printers with a heatedprint head and ribbons with coating on one side. The print head expresses heatonto the ribbon, transferring the desired pattern to label material passingthrough the printer. The ink from the ribbon forms a long lasting and durableprint on the label, due to which thermal transfer labels are ideal forlong-term and outdoor use. The print quality, clarity and definition aregreater than that of direct thermal labels, and multiple colours can be used.Thermal transfer labels are weather resistant and a wide range of materials canbe used for the labels. While the costs of label stock can be low, there areadditional printing costs involved due to replacements of the printer ribbons.

Advantages:

Durableand heat-resistant
Canhave multiple colours
Suitablefor high definition images and barcodes
Widerange of compatible label materials
Fastprinting

Disadvantages:

Additionalcosts for printer ribbons
Greaterdowntime due to replacements of ribbons and label materials
Ribbonsand label materials must be compatible

Comparison of Direct Thermal and ThermalTransfer Labels:

Selecting and setting up a labelling system isa big decision, and does involve investment of money and time. While thebenefits are abundant of having an in-house labelling setup, the decision ofwhich type of labels will depend upon your labelling needs. Every type of labelcomes with its own advantages and disadvantages, and needs to be compared withits relevant applications in your business. If you are upgrading or switchingfrom an existing labelling setup, consider what worked and didn’t work, andwhat you wish you could have done differently.

Printing Technology

The printing technology used by your labelprinter will have a major impact on the quality of labels, compatible labelrolls, durability and overall costs. The label printer will be the single mostexpensive component of an in-house labelling setup and a one-time purchase. Incomparison, consumables like the label materials, and ribbons (if applicable)are relatively low cost and need to be purchased frequently, giving more scopefor experimentation. The size of the printer also matters if you have limitedspace available.

DirectThermal Labels: To produce direct thermal labels, direct thermal printers areused where a heated print head reacts with specialised heat sensitive labelmaterial to create the desired patterns. Direct thermal printers are compact,and do not require any additional inks or ribbons, only specially treated labelmaterials. It is easy to print direct thermal labels, and also cost-effective,although the durability is limited and multiple colours are not supported. Asthere are limited moving parts, direct thermal printers are less likely tobreakdown or require maintenance, giving greater reliability. Poor qualitylabel materials should be avoided to prevent damage to the print head, which isdirectly in contact with the label materials.
ThermalTransfer Labels: To create thermal transfer labels, thermal transfer printersare used, where a heated print head presses against ink ribbons to printdesigns on label material passing through the printer. For quality labelprinting, it is necessary that the ribbons and label materials be fullycompatible. Thermal transfer printers are sturdy and can be setup indoors or outdoors,and in nearly any temperature setting. As ribbons are used between the printhead and the label materials, wear and tear of the print head is reduced,giving the printer a longer life. The label materials do not need to have anyspecial characteristics for thermal transfer printing, and so a wide range ofmaterials can be used.

Applications

The most important factor to influence yourchoice of labels should be the intended applications of the labels. Over theyears, the uses of labels have evolved and diversified, and they now servemultiple purposes ranging from informing, to identifying, warning, instructionsand advice. For businesses involved in the sale of large volumes of products,labels are useful for inventory management and at point of sales. With theflexibility of adhesive capabilities, labels can be attached almost anywhererequired.

When identifying the intended applications fora labelling system keep in mind who would be the targeted user, the purpose ofthe label, and the environment it would be in. For employee usage you can optfor more basic labels, while for customers having colourful and eye-catchinglabels would be beneficial. The applications of the labels would also influencethe durability requirements. Products with a long shelf life or those placed inoutdoor environments would require more durable labels as compared to indoorand short shelf life products.

DirectThermal Labels: Cost-effective and easy to print with a short to medium lifespan, direct thermal labels are ideally suited for indoor applications. Theyare great for applications such as retail, logistics, price labels, coupons,barcode systems, shipping labels, weight labels, meat labels, tags, priceweight labels, compliance labels and temporary name tags. When printed onsynthetic media, direct thermal labels are also useful for labelling freezeritems that are exposed to cold temperatures and moisture. Although directthermal labels are primarily available in black, by using a coloured labelmaterial, the labels can be made more striking. Direct thermal labels areimmensely versatile, but are not suitable for environments with hightemperatures.
ThermalTransfer Labels: With support for good quality and high definition prints,thermal transfer labels have excellent durability and a long shelf life, makingthem suitable for a wide range of applications. The right combination ofribbons and label materials can be used to create any type of thermal transferlabels for indoor or outdoor use. Popular applications include product labels,promotional labels, permanent labels, certifications, chemical labels, outdoortags, laboratory labels, asset tracking and branding labels. Thermal transferlabels can be colourful and vivid, while also being long lasting. They are excellentfor promotional purposes as thermal transfer labels are eye-catching and longlasting.

Printing Quality

The expected quality of the printed labels isan important factor to consider when choosing label types. The basic goal oflabels is to convey information to the viewer; however, it matters who theviewer is and what kind of information is to be conveyed. If the labels are forstore personnel usage, for example, in a storeroom setup or for inventory,simple and straightforward labels can work. If the labels are intended forcustomers, to inform them about a product, or to encourage a purchase, thelabels need to be of better quality. The printing quality also matters if youare printing barcodes, as some barcodes involve greater density patterns andrequire sharper printing.

DirectThermal Labels: The printing quality of direct thermal labels is decent withadequate clarity and consistent performance. The labels can support printedtext, 1D barcodes and 2D barcodes that are readable and scannable. While theprinting quality is fine for basic tasks, only black coloured printing isavailable, or with specialised label materials you may get one more colour.Direct thermal labels are prone to smudging and can be damaged by heat, whichcan damage the print quality if not carefully handled.
ThermalTransfer Labels: With thermal transfer labels you get high print definition fortexts, barcodes and images. The labels can include a combination of printingsmall characters, line work, logos, 1D barcodes and 2D barcodes. Ribbons areavailable in resin, wax and wax resin grades and a vast variety of shades toprint colourful labels that are useful for branding and promotions. Thermaltransfer labels are durable, scratch resistant and heat resistant, due to whichthey can better maintain good quality prints.

Label Materials

The material used for printing the labels willhave a significant impact on the final printing quality of the label, itsapplications, durability and cost. Commonly used label materials includepapers, polyester, vinyl, polypropylene, foils and other blends. Among thelabel materials, there are different finishes available, including matte,glossy, semi-gloss, fluorescent, reflective and transparent.

The label materials that you can use willdepend upon the printing technology used by your label printer. If the labelmaterial and printing technology are not compatible, you can end up with poorquality and blurry labels. Fully compatible label materials and printers willproduce clear, crisp, and good quality labels. The adhesive capabilities oflabel materials vary from removable and temporary adhesives to more long-termpermanent adhesives.

DirectThermal Labels: When it comes to direct thermal labels, there are relativelyfewer label material options available. As there are no ribbons or inksinvolved, the label material needs to be specialised and heat sensitive inorder to print the desired pattern. While some direct thermal label rolls canbe used for thermal transfer or other printing technologies, only dedicateddirect thermal materials can be used for direct thermal printing.
There are primarily two types of labelmaterials available for direct thermal labels, and these are papers andplastics. Papers are suitable for most general purpose direct thermal labelswhile plastics support better durability and resistance to chemicals, moistureand abrasion. The cost of direct thermal label materials is higher than generallabel rolls, however, since no inks or ribbons are involved, the overallprinting cost for the labels remains low.
ThermalTransfer Labels: There are a wide range of label materials that can be used forthermal transfer labels, as ribbons are used to print the desired pattern.However, it is necessary that the material be compatible with the ribbons inorder to get the desired printing quality and durability. While there arededicated thermal transfer label materials available, most general label rollsalso support thermal transfer label printing.
The most popular label materials for thermaltransfer labels are papers, plastics and polyesters, although films, foils,vinyl, and mixes can also be used. Papers are suitable for high definitionprints with strong adhesives. Plastics have great resistance to smudging andwater, and are also immensely flexible, and can be used for a variety ofsurfaces. Polyesters provide the best durability and are waterproof, scratchresistant and tear resistant, making them ideal for outdoor applications. Thecosts of thermal transfer label materials vary, and depends upon the quality ofthe material, adhesives and finishes.

Label Durability

The durability of a label reflects itscapability of withstanding wear and tear, high temperatures, and roughhandling, along with its general life span. When choosing a labelling setup, itis vital to consider the required durability of the label as different types oflabels have different strengths, capabilities, and longevities. The durabilityof a label is dependent on multiple factors, including the printing technologyused, the label material and ribbons, but the printing technology has thebiggest impact.

Consider the desired applications of yourlabels, type of environment the labels would be in, and the desired life cycleof the labels. For example, if the labels are to be used mainly indoors in atemperature-controlled environment, then heat-resistant labels might not beneeded. In comparison, if the environment may become hot, or the labels arebeing used outdoors, weather resistant labels can be a good option. Fortemporary labelling needs, you can opt for labels with a small to medium rangelife span, while for more permanent labelling requirements you can choose moredurable long-term labels.

DirectThermal Labels: The durability of direct thermal labels is limited, since thelabel materials are heat sensitive and the design is printed without any inksor ribbons. They are most suitable for indoor applications and have a short tomedium lifespan, tending to fade over the course of 6-12 month. As the directthermal labels are heat sensitive, overexposure to UV light and heat can damagethe prints on the labels. There is limited abrasion resistance and scratchingthe labels can lead to smudges. Using good quality label materials such asplastics can increase the durability of direct thermal labels to a certainextent.
ThermalTransfer Labels: When thermal transfer labels are printed, ink from the ribbonsis absorbed into the label material, creating labels with high definitionquality and excellent durability. Thermal transfer labels are ideal forlong-term and outdoor applications, and can easily last for over a year. Theselabels can withstand extreme temperatures, harsh industrial processes,laboratory processes, cleaning solvents, fuels, weathering, UV exposure, andindustrial fluids. The thermal transfer labels are not damaged by frequenthandling, abrasions, humidity or moisture. There are numerous types ofadhesives available with thermal transfer labels, so that you have fullflexibility in how long you want the label to stick.

Speed

A big advantage of having an in-houselabelling setup is that you can print labels whenever you need them, in as muchvolume as you require. However, if you have instant needs for customisedlabels, then it may help to consider the speed and reliability of labelprinting when you choose a labelling setup.

Although there are variations with specificprinter models, the speed and reliability depend upon the printer technology,how fast it can print, and how much downtime is likely. If you do not have requirementsfor fast labels and are likely to pre-plan any label printing, then slowerprinting speeds can also work. In general, thermal printing is fast, but thereare slight differences between printing direct thermal labels and thermaltransfer labels.

DirectThermal Labels: Printing of direct thermal labels is reasonably fast andefficient. Since there are fewer moving parts, with only the print headcreating the design against heat sensitive label materials, there is minimalchance of malfunctions requiring repair. With no ribbons involved, and quicklyloading label rolls, direct thermal labels can be printed at any time, wheneverrequired.
ThermalTransfer Labels: For thermal transfer labels, the ribbon transfers the inkdirectly to the label material, making the printing speed faster than mostdirect thermal printers. However, as there are more moving components in athermal transfer printer, including for the ribbons, these printers oftenrequire repair and maintenance. Replacing the ribbons also takes time,increasing the downtime of printing thermal transfer labels.

Costs

The benefits of an in-house labelling systemmake it well worth the investment, but it does involve costs to setup. Thebiggest cost will be of the label printer, and subsequently you will need tofactor in costs of consumables such as label rolls and inks. There may also beoccasional repair and maintenance costs. Consider the applications of labelsfirst so that you know which type of labels you can invest in.

DirectThermal Labels: The cost of a direct thermal label printer is low, and thereare no recurring costs for any ribbons or ink. However, the label materials needto be specialised and heat sensitive, due to which the cost of label rolls canbe higher. The printer head tends to wear out faster because of direct contactwith label materials, so you may have to replace the printer head at somepoint. Overall, the per label print cost is low, and the printer cost is alsolow.
ThermalTransfer Labels: A thermal transfer printer tends to be more expensive andthere are additional recurring costs for replacing ribbons as per usage. Labelmaterials are available in a variety of price points, depending on the type ofmaterial. In general, the maintenance costs are higher for thermal transferprinters since there are multiple moving parts. However, the print head has alonger life because ribbons act as a buffer between the label material. Thecost per label and for the printer are higher, but you also get better printingquality, coloured labels, and greater durability.

Conclusion

The popularity and importance of labelscontinue to rise as the applications of labels diversify and grow. Thermallabels are the most commonly used type of labels, offering fast and goodquality label, including high volume printing. Nevertheless, there aresignificant differences between direct thermal labels and thermal transfer labels.

Direct thermal labels are cost-effective andhave good clarity with a short life span, making them ideal for temporary andindoor applications. For high definition and colourful labels, thermal transferlabels are a better choice and are durable for long-term and outdoor use. Whenselecting a type of label, consider its applications in your business, theprinting quality required, and the durability expected.

Reachout to POS Plaza for help in finding the best labelling setup for yourbusiness needs, including direct thermal and thermal transfer label printers,label rolls and ribbons.

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