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Thermal barcode printers are specialized printers designed specifically for printing barcode labels, tags, and wristbands. As the name suggests, thermal barcode printer use heat to print on thermally sensitive media rather than ink.
A heating element inside the printer head heats up to produce an image on the label material as it passes through the printer. The heat causes a chemical reaction that turns the coating black on the label material. This allows for printing text, graphics, and barcodes quickly and efficiently.
Thermal barcode printers are extremely fast, reliable, and cost-effective. They are capable of printing at speeds of 6-12 inches per second and are ideal for high volume barcode printing applications. Most thermal barcode printers can print 600 dpi resolution for crisp, readable barcodes.
How Do Thermal Barcode Printers Work?
The core technology behind thermal barcode printers is Direct Thermal (DT) printing. DT printers contain a print head with hundreds of tiny heating elements across the surface. When a command is sent to print a label, the heating elements are heated rapidly in a precise pattern.
As the label material passes through the printer, the heated elements make contact with the thermo-sensitive coating on the material which turns black. This produces the text, graphics, and barcodes on the label.
After printing, the heating elements are cooled back down in preparation for the next label. This process of rapidly heating and cooling the individual elements enables high speed printing.
Many thermal barcode printer also support Thermal Transfer (TT) printing. TT printing introduces a ribbon coated in wax or resin that melts when heated. The print head heats the ribbon and causes the ink/resin to transfer onto the label material.
TT printing provides greater durability for printed labels exposed to abrasion, chemicals, or outdoor elements. However, the ribbons have an associated consumable cost while DT printing does not require ribbons.
Advantages of Using Thermal Barcode Printers
Thermal barcode printers offer numerous benefits that make them the go-to choice for barcode printing in many industries:
Cost-Effectiveness
One of the biggest advantages of thermal barcode printers is their low operating costs. Because thermal barcode printers do not require ink or toner, the only consumable cost is the label/tag media. This results in very low cost per label printed.
Thermal printers are energy efficient as well since they don’t need heat for the entire print area. The individual heating elements provide pinpoint accuracy to produce images and barcodes. This saves electricity consumption over time.
High Print Quality
Leading thermal barcode printers on the market today can print extremely crisp, detailed barcodes and text. Using Direct Thermal printing, resolutions up to 600 dpi are possible for precision barcode printing.
This ensures accurate barcode scanning and readability. Print quality remains consistent over the life of the printer as there are no issues with print heads clogging unlike inkjet printers.
Flexible Media Options
Thermal printers support a wide variety of label and tag materials including paper, polyester, vinyl, and specialized synthetics. Media comes in different sizes and thicknesses.
Common sizes used are 4×6, 4×8, 4×12 inches. Some printers support linered and linerless media rolls. This versatility allows businesses to choose suitable media for their specific application and barcode needs.
Fast Printing Speeds
A key advantage of thermal barcode printers is very fast print speeds. Most industrial barcode printers have speeds between 6 to 14 inches per second. This enables high volume barcode printing with minimal wait times.
Thermal printers do not have any warm up periods required before printing like laser printers. This makes them ideal for printing batches of barcodes on demand.
Low Maintenance Requirements
Thermal barcode printers are designed for reliability and minimal maintenance. There are no print heads to clean or replace periodically. No ink or toner is required. The only maintenance needed is occasional cleaning of dust, debris and label residue from the print path.
This results in low maintenance requirements and downtime. Thermal printers can handle heavy duty printing applications and high duty cycles without frequent service needs.
Disadvantages of Thermal Barcode Printers
While thermal barcode printers have many benefits, there are some downsides to consider:
Susceptibility to Heat and Humidity
The thermal print heads are sensitive to operating conditions with high heat and humidity. Print quality and printer life can degrade if used consistently in hot, humid environments. Proper ventilation and climate control is recommended.
Potential Fading Issues
Direct thermal printed labels have potential to fade or discolor when exposed to prolonged sunlight or chemical contact. Using a Thermal Transfer printer with durable resin ribbons increases fade resistance.
Limitations with Non-Porous Surfaces
Thermal printers have difficulties printing on very smooth, non-porous surfaces like metal, glass, wood, etc. The smooth surface prevents the thermal ink from bonding properly. Using label media with strong adhesives can improve bonding on such surfaces.
Key Factors to Consider When Buying a Thermal Barcode Printer
There are several important considerations when choosing a thermal barcode printer to meet application needs:
Print Resolution
Higher print resolutions produce sharper, more detailed barcodes. Look for printers that support at least 203 dpi but ideally 300 dpi or 600 dpi for maximum barcode print quality.
Print Speed
Print speed determines how fast the printer can print barcodes. Industrial barcode printers print 6-14 inches per second or more. Choose appropriate speed for printing volume.
Connectivity Options
Look for flexible connectivity via USB, Ethernet, Bluetooth, Wi-Fi. Serial and parallel ports are older but still used. Having multiple options ensures easy setup.
Supported Barcode Symbologies
Verify the printer supports all the 1D and 2D barcode symbologies needed like Code 128, Data Matrix, QR Codes etc.
Printer Size and Portability
Small desktop printers or compact mobile printers may be needed depending on available space and portability needs.
Media Compatibility
The printer must support all required media widths, thicknesses, materials, and roll diameters used.
Software and Drivers
Ease of integration and compatibility with operating systems or other software platforms being used is essential.
Leading Thermal Barcode Printer Brands and Models
Some top manufacturers making quality thermal barcode printers include:
Zebra Technologies
Zebra is the global leader in barcode printers manufacturing industrial, desktop, mobile, and specialty barcode printers. Top models include the Zebra ZD410, ZD420, ZT410, ZT420, and ZQ520.
Honeywell
Honeywell is another leading brand with a wide range of barcode printers like the PC42t, PM4i, PB2, PB22, PB50, and PX4i.
SATO
SATO makes high performance thermal barcode printers like the CL4NX, CL6NX, CT4-LX, and FX3-LX series.
iDPRT
iDPRT barcode printers are renowned for their high performance and cost-effectiveness. Among the most popular models are the SP410, SP410BT, SP420, iT4S, and iX4L series.
Toshiba TEC
Toshiba TEC barcode printers are known for their reliability and low maintenance. Popular models are the B-EX4T1, B-EX4T2, B-EX6T1, and B-SX8T series.
Epson
Epson ColorWorks and LabelWorks thermal barcode printers deliver vibrant color printing. Leading models are the Epson TM-C7500, TM-C7500G, and ColorWorks C7500/C7500G.
Printronix
The Printronix T8000 and T6000 series are heavy duty industrial thermal barcode printers designed for mission-critical supply chain applications.
Applications and Industries that Use Thermal Barcode Printers
Thermal barcode printers are used across many industries due to their versatility, reliability, and cost-effectiveness.
Shipping and Logistics
High volume shipping, warehousing, and logistics operations rely on thermal barcode printers for barcode labels on packages, pallets, containers, and more.
Retail and Point of Sale
In retail, thermal barcode printers are ubiquitous at POS stations for printing price tags, markdowns, receipts, coupons etc.
Healthcare and Hospitals
Patient wristbands, pharmacy labels, specimen labels, and asset management tags are commonly printed with compact thermal barcode printers in healthcare.
Manufacturing and Warehousing
Product labels, manufacturing work in progress tags, parts inventory labels etc. often leverage thermal barcode labeling in manufacturing facilities and warehouses.
Government and Security
Thermal barcode printers produce IDs, access control badges, law enforcement tickets, and other tags where durability and security are critical.
Tips for Maintaining and Optimizing Thermal Barcode Printers
To keep thermal barcode printers performing optimally and extend their lifespan, follow these maintenance best practices:
Use High Quality Media
Low quality barcode media with poor coatings can degrade print heads faster. Use reputable supplies for optimal print quality and head life.
Clean the Print Head
Buildup of dust, adhesive, and residue on the print head can impact performance. Clean regularly using isopropyl alcohol/cotton swabs.
Calibrate the Sensor
The media/ribbon sensor can fall out of alignment over time. Calibrate sensors as needed to maintain proper alignment.
Keep Firmware Updated
Updating printer firmware provides access to latest features and fixes. Always keep firmware up to date for optimal functionality.
Control the Operating Environment
Avoid extreme heat, cold, humidity, dust, dirt etc. which can hasten wear and breakdowns. Maintain stable, clean operating environment.
The Future of Thermal Barcode Printing Technology
Thermal barcode printing technology continues to evolve with new innovations enhancing print speeds, quality, connectivity, and reliability. Here are some developments on the horizon:
- Higher print resolutions like 1200 dpi will enable ultra-sharp barcodes rivaling laser printers.
- Faster print speeds of 16-24+ inches per second will drive new high-volume applications.
- Enhanced wireless/Bluetooth connectivity and support for new protocols will simplify integration.
- New label materials and coatings will increase durability for demanding industrial uses.
- Smart chip technology will allow barcode labels to capture and transmit data to cloud systems.
- Color thermal printing will expand from just color logos to full process color printing.
- Security features like encryption will enhance protection for printed barcodes and product labels.
- More compact and portable printer designs will increase mobility and convenience.
As technology improves, thermal barcode printing will become even more cost-effective, versatile and integral to supply chain management.
Conclusion
Thermal barcode printers provide a specialized printing solution optimized for barcode labeling and tagging operations. They deliver fast, high quality barcode printing on demand at a low cost per label printed.
Leading thermal barcode printer brands offer a diverse range of desktop, industrial, and portable models to meet diverse business needs. With continual improvements to print speed, quality, durability, and connectivity, thermal printers will continue advancing barcode printing technology into the future.
Businesses and organizations in every industry can benefit from incorporating thermal barcode printers into their operations for tracking products, assets, inventory, shipments, and more. Their versatility and reliability make thermal printers the go-to choice for enterprise barcode printing needs across supply chains.
Frequently Asked Questions
What types of barcodes can thermal barcode printers print?
Thermal barcode printers can print all standard 1D barcodes like Code 39, Code 128, EAN-13, UPC, as well as 2D barcodes like Data Matrix, QR Codes, PDF417. Advanced printers support dozens of symbologies.
How long do thermal barcode labels last?
Direct thermal labels typically last 1-5 years if kept indoors and not exposed to prolonged sunlight or chemicals. Thermal transfer labels printed with durable resin ribbons last 5-10+ years for long-term barcode identification.
Can you print expiration dates and batch numbers on thermal barcode labels?
Yes, thermal barcode printers can print variable data like expiration dates, lot numbers, serial numbers etc. on each label using built-in or PC-connected software.
Are thermal barcode printers better than inkjet or laser printers?
Thermal printers are superior to inkjet and laser for dedicated barcode printing applications given their speed, barcode print quality, reliability, and lower cost per label. They are optimized specifically for barcode label printing.
What barcode scanner types can read thermal printed barcodes?
Thermal printed barcodes can be read reliably by any type of barcode scanner including laser, CCD, camera-based scanners, and more as long as the scanner supports the barcode symbology printed.
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