An industrial label printer is purpose-built to perform in demanding industrial and logistical environments. These printers set themselves apart by their rugged design and the output requirements of printing thousands of labels a day with ease.
In this article, we will dive into the specifics of the industrial label printer and further explore the intricate details of thermal transfer technology, a cornerstone of industrial label printing.
Key features of industrial label printers:
- Durability: Industrial label printers are built to withstand harsh industrial environments, making them ideal for use in warehouses, manufacturing facilities, and other demanding environments.
- Prints: They are designed to print labels quickly and efficiently, helping you minimise downtime and increase productivity.
- Connectivity: Many printers offer a variety of connectivity options, including Ethernet, USB, and wireless, allowing for easy integration into existing systems.
- Label size and material compatibility: Industrial label printers can accommodate a wide range of label sizes and materials, including polyester, vinyl, and heat shrink tubing.
- Barcode printing: These printers are capable of printing high-quality barcodes, making them ideal for applications requiring tracking and inventory management.
When selecting an industrial label printer, consider factors such as the type of printing technology, print speed, connectivity options, label size compatibility, and budget. It is also important to choose a reputable manufacturer with a track record of producing high-quality printers.
The different industrial label printer technologies
Before we dive into the specifics of thermal transfer, let’s take a moment to understand the landscape of industrial label printing technologies. Consider the choice between two main technologies inkjet and thermal printing technologies, each offering unique advantages and considerations. While inkjet printers excel in producing vibrant colors and high-resolution images, thermal printing stands out for its durability and reliability in industrial settings.
As we navigate the realm of industrial label printers, we will uncover the nuances of direct thermal and thermal transfer printing methods, each serving distinct purposes in the realm of labeling. Direct thermal printing is ideal for quick printing tasks like receipts and logistical labels, while thermal transfer printing shines in applications requiring long-lasting and durable prints.
Inkjet printing technology
With inkjet printing, the printhead is used to propel tiny droplets of ink towards a substrate, where the image or text is shaped. Inkjet printers provide a lot of options in print colour and are able to produce high resolution images. Often, durability is a weaker point for images and text printed with inkjet.
Thermal printing technology
Thermal printing uses heat to shape the image or text on a substrate. Thermal printing can be done in two ways: direct thermal and thermal transfer printing. Many thermal printers are able to print via both methods, depending on if an ink ribbon is placed (thermal transfer) or not (direct thermal).
Direct thermal printing technology
With direct thermal printing, the image appears when the heat from the printhead changes the colour on special, thermo-sensitive, material. This method is mostly used for quick printing of things like receipts and logistical labels that do not need a lot of longevity or durability. When a more durable, long-lasting print is required, TTR technology is the logical choice.
Thermal transfer printing technology
Thermal transfer printing uses the heat from the printhead to transfer the image from an ink ribbon onto a substrate. The combination of the Thermal Transfer Ribbon (TTR), the substrate and the settings of the printer determine the durability of the print. The most durable prints are able to withstand temperatures above 300°C, contact with aggressive chemicals and severe abrasion, while remaining readable for decades.
Additionally, thermal industrial label printers are smaller in size and require lower investment while generally also requiring less maintenance. An industrial label printer working with inkjet technology, on the other hand, has the advantage that it does not require ribbon changes.
Types of thermal transfer printers
Industrial label printers using thermal transfer technology are offered with two types of print-heads: flat-head and near-edge.
- Flat-head: The design of flat-head print-heads ensures a long exposure time of the print-head to ribbon and substrate. This exposure time provides the most options in securing the print onto the substrate, resulting in the most durable print result. An industrial label printer with a flat-head print-head usually prints slower than printers with a near-edge print-head.
- Near-edge print-heads are designed for speed and are seen on the industrial label printers with the highest volume requirements. They can often be found in production lines utilising the so-called Thermal Transfer Overprint technology.
The type of printer should be selected depending on the application and durability requirements of the print. Also note that both types of printheads require different types of thermal transfer ribbons.
The 3x different thermal transfer ribbon categories for industrial label printers
The right thermal transfer ribbon, or TTR, is a key component in successfully using your industrial label printer . Each thermal transfer ribbon consists of several components, of which a PET carrier film and an ink layer are always part of the composition..
TTR can be divided in 3 main groups:
- Wax ribbons are commonly used on flat-head printers. By design and composition, these ribbons are very suitable for the printing of rough substrates, such as uncoated paper, as they are able to overcome unevenness and still produce a dark and crisp print result. Wax ribbons are easy to print and they provide basic durability.
- Wax-resin ribbons are the go-to option when more durability is required compared to a wax printed substrate. Near-edge wax-resin ribbons are generally designed for the highest production speeds.
- Resin ribbons provide the highest possible durability of the print. Most resin ribbons are designed for flat-head printers while options for near-edge are also available. Specific resins also contain an adhesive layer that is activated by the heat of the print-head. This adhesive layer enables the printing of hard-to-print substrates as it creates a fusion between the ink and the surface of the label.
The main difference in design between a flat-head and a near-edge ribbon is the release layer, this is the layer between the carrier film and the ink. For high volume industrial label printers, the fast release of the ink is crucial to meet the output requirements.
Apart from selecting the right formulation, it’s also crucial to opt for a high quality product. Most importantly, because in many industrial environments, a lot of dust is present. Dust in the printer can affect both the quality of the print, and the life of the print-head. Static electricity is attracting dust to the printer and print-head. Therefore, it is important to reduce the build-up of static in your industrial label printer. The selection of a good quality ribbon helps in achieving this. Good quality ribbons have an anti-static layer on the side of the ribbon that contacts the printhead. This layer prevents the build-up of static electricity and thereby the collection of dust on the print-head.
Industrial printer labels used for printing with thermal transfer printing
Industrial printer labels are made from a wide range of materials: from uncoated paper to high-end synthetics.
Which substrate is chosen for different industrial printer labels, very much depends on the durability requirements and expected exposures. Other important factors include the need for certain certifications (UL, Isega) or other industry specifics.
Once the substrate has been selected, the next important step in achieving the optimal print result is to match it with a suitable TTR.
From a substrate point of view, the surface of the label is a key factor in the ribbon matching. Substrates with a rough surface, such as uncoated paper and Tyvek® require a different ribbon compared to smooth surfaces such as PET and vinyl.
For industrial printer labels with a rough surface, the challenge is to overcome the roughness, meaning that a way should be found to keep the ink on top of the surface. Failing to do so will result in a grey print where readability becomes an issue. Wax is an important component in overcoming the roughness of the surface as wax has the ability to melt into the unevenness while enough of the ink remains on top to ensure optimal readability. Generally speaking, ribbons for rough labels are made with wax or wax-resin, although some ribbon manufacturers have been able to develop resin ribbons that are able to print on these substrates.
Very smooth industrial printer labels need a totally different approach in terms of ribbon selection. A very smooth substrate surface often results in the ink being easily wiped off. In order to prevent this, the ink needs to be fixed to the surface through an adhesive. Specific thermal transfer formulations include such an adhesive, enabling a strong fixation of the ink to the industrial label surface by applying the right amount of heat through the print-head.
High quality suppliers of thermal transfer ribbons, labels and printers will be able to advise and support you in finding the best options for your specific situation.
Typical uses of industrial labels printers using thermal transfer technology
As mentioned before, industrial label printers are an essential tool for many industries such as automotive, cosmetics, food and beverage, or pharma and healthcare companies. These printers play a crucial role in ensuring that products are labeled accurately and efficiently.
Let’s take a look at a real life example. One of DNP’s distributors had supplied our thermal transfer ribbons to a major pharmaceutical company during the pandemic. This company relied on industrial label printers, to print variable information on their vaccines as they move through the manufacturing line. The client was searching for the right ribbon and label combination with the ability to withstand specific cold temperatures their vaccines are exposed to throughout the storage and delivery processes. And so, one of the key components in the printing process became V300, DNP’s highly versatile resin ribbon.
Using V300 with the right labels enabled our client’s customer to accurately label their vaccines with important information such as expiration dates, lot numbers, and dosage instructions. This not only helped them ensure regulatory compliance, but also provided peace of mind to both the company and their customers, knowing that the vaccines have been properly labeled and tracked throughout the manufacturing process.
Harmonising printer, label and ribbon
When you look at different production environments and durability needs, it becomes clear that the selection of ribbon, substrate and printer is just the first step of the selection process. Once all components for your print are selected, it is important to carry out testing and find the right settings that bring these elements in harmony.
Depending on the combination of substrate and ribbon, the printer needs to be set to work on right temperature, speed and pressure-settings. Fine-tuning these will ensure the optimal print results:
- Heat settings: The correct temperature is important to properly release the ink, activate a possible adhesive layer and create a dark and crisp image. Depending on the ribbon and substrate, different temperature settings are applicable. Wax ribbons print at lower temperatures while the most durable resins require the highest possible temperature settings.
- Speed settings: The chosen print speed has a big impact on the print result and needs to be harmonised with the temperature and pressure. When the temperature is too low or the speed is too high, the print looks faded or grey. Too high temperatures or too low printing speeds give a print that looks too thick and heavy.
- Pressure settings: A last feature that many printers provide is the setting of the pressure that is applied by the printhead. This provides additional options when determining the speed and temperature settings.
When the right settings have been determined, industrial label printing can help you deliver the variable print excellence you are seeking and provide peace-of-mind in ensuring smooth running operations.
In conclusion
In conclusion, the world of industrial label printers and thermal transfer technology offers a fascinating glimpse into the intricate details of printing technology. From the durability and efficiency of industrial label printers to the importance of selecting the right thermal transfer ribbon and substrate, it’s important to consider several key factors when navigating this specialised field. By harmonising the components of printer, label, and ribbon, you can achieve optimal print results and ensure smooth operations in a variety of industries. Embracing the advancements in industrial label printing technology can help you manage organisation, productivity, and efficiency in your day-to-day operations.
