Why the Right Barcode Label Matters and How to Avoid Costly Mistakes

As simple as barcode labels seem, things can get a lot more complicated and costly if you don’t match the right barcode labels and printing supplies with the job you need your labels to perform.

In this article, our barcode label printing experts at SK&T will explain the potential issues that can arise if you opt for cheap labels or fail to carefully assess your specific labeling needs. We’ll discuss the importance of choosing the right labels with the appropriate materials and adhesive to ensure proper adhesion, readability, scannability, and durability.

In many cases, companies choose basic, cheap barcode labels and don’t pay much attention to application, environmental, and durability factors, and this proves to be a costly mistake in the long run, often costing them thousands or even tens of thousands of dollars.

But this is easy to avoid with a bit more care and attention as you’re getting ready to procure your labels and choose the right labels and printing supplies. We’ll show you how to do it, and let’s start with understanding how something as simple as a barcode label can become an expensive headache if you get it wrong.

When Barcode Labels Fail: The Consequences of Poor Label Choices

If you’re choosing labels for short-term or simple requirements, such as shipping or office use, where your labels are only going to be used for a short time, on flat and easy-to-adhere surfaces, and they don’t need to provide any kind of long-term or serious durability, then it’s usually fine to choose a standard paper barcode label. But most applications aren’t this simple, and if you choose a standard paper barcode label for these other jobs, you’ll likely face any number of serious and expensive problems.

Here are some common problems that we often see when companies don’t match the right barcode label and printing supplies with specific application, usage, and durability requirements:

Adhesion failures. Your label will fall off or detach from the labeled surface.

Durability failures. Your label or adhesive becomes unreadable and unscannable over time, due to exposure to sunlight, extreme temps, chemicals, moisture, abrasion or other factors.

Application Problems. Using a non-specialized label at certain application temperatures or with a label applicator can cause problems with initial adhesion or the ability to peel the label away from the liner.

Excessive printhead wear. Cheap, basic labels made of substandard materials are often rougher and cause premature and excessive printhead wear and expensive printhead replacements.

Excessive printhead buildup. The wrong match of label and ribbon type can mean you’ll end up using more ribbon and higher darkness to get the readability and scannability you need, and this can cause excessive buildup on your printhead and wear it out far too soon.

These issues can result in thousands of dollars in long-term costs. Printhead failures alone can quickly add up to thousands of dollars. Additionally, whenever a label falls off, becomes unscannable or unreadable, or cannot be applied properly, it can lead to time-consuming interruptions, reprints, troubleshooting, and even the loss of valuable assets or inventory.

How to Pick the Right Label for Any Job

The best way to avoid label adhesion, performance and durability issues, and avoid costly disruptions or printhead replacements is to always take the time to match the right label and printing supplies to the right job. This starts with understanding which type of printing and label is best for your job, and that begins with determining the lifespan and durability you’ll need.

Label Selection Criteria: Printing Type, Lifespan and Durability

If you need a label that will last longer; provide durability against extreme temperatures, abrasion, moisture, chemicals or other more demanding conditions; and/or might need to adhere to round or unusual surfaces, then you’ll likely need to use a thermal transfer printer and label.

Thermal transfer printers use a thermal printhead to apply heat to a printer ribbon, which melts ink onto the label, forming a much more durable image. Additionally, specialized thermal transfer label materials and adhesives can help ensure that your labels remain adhered, scannable, and readable in more extreme conditions. When exposed to moisture, chemicals, or abrasion, they won’t fall off, fade, get scratched, smudge, or suffer other types of damage.

In many use cases, these specialized thermal transfer labels are the ideal solution, since they provide much longer life and durability. On the other hand, direct thermal labels are an alternative for situations requiring a short lifespan and low durability. A direct thermal label uses heat transfer to create an image directly on the paper. No ink, toner or ribbon is required with direct thermal printing. This is often the right choice for basic shipping and office labels, but your printed barcodes and images will have much more limited durability, and they might not work well for curved or other unusual surfaces.

Thermal Transfer Ribbons

If you’ve decided to use a thermal transfer printer and labels, you’ll need to choose the right label for your specific job as well as the appropriate thermal transfer ribbon. This ensures that the printer can apply heat to the ribbon, transferring longer-lasting ink onto your labels.

There are three main types of thermal transfer ribbons:

1. Wax Ribbons are ideal when you need your printed information to last longer, but the labels won’t be exposed to harsh chemicals or significant abrasion.

2. Wax/Resin Ribbons are used when you need longer-term durability for your printed labels, especially if they will be exposed to moderate abrasion, harsh chemicals, or if UL/cUL approval is required.

3. Resin Ribbons are used in cases where your labels and printed information not only need to withstand extreme chemicals but also harsh abrasion. They’re also a good fit if your labels require UL/cUL approval.

Curved or Unusual Surfaces

If you need your label to adhere to a curved or otherwise unusual surface, you may need a label with a high-tack or other specialized adhesive, so you don’t have issues with your label peeling away, detaching, or falling off.

Extreme Temperatures

When selecting your label, it’s important to consider both the application temperature and the service temperature. The application temperature refers to the temperature range during the label’s application, while the service temperature is the range of temperatures the label will be exposed to during its use over time.

Standard paper labels with direct thermal printing often perform well enough when the application temperature is at least 25°F and the service temperature is -65°F to 200°F. However, for any temperatures outside these ranges, then you’ll need to use a thermal transfer printer and label, and you will likely need a specialty adhesive as well.

Chemical and Moisture Resistance

Chemical exposure can damage your labels and printed information. If your labels are exposed to any chemicals, including water, it’s best to use a thermal transfer printer and labels. In most cases, you’ll also need a resin ribbon to ensure the long-term durability of the printed image.

Abrasion

We’ve already discussed the durability requirements for thermal transfer ribbons, but it’s important to highlight abrasion as a separate factor to consider. If your label needs resistance to abrasion created by occasional or frequent rubbing or scratching, then you should use a thermal transfer ribbon with a higher resin content. A wax/resin ribbon or a resin ribbon will be the right choice, depending on how much abrasion resistance you need. A resin ribbon will provide the most protection against abrasion.

Label Applicators

If you’re applying your labels with a label applicator, then your label will need to be cut differently, to allow it to peel off properly from the liner. Perforations are not a good option because they change label stiffness and make it more difficult to release the label from its liner. You can choose and order specialized labels that are the right option for label applicators.

Indoor/Outdoor Use

If your label will be regularly exposed to outdoor conditions such as sun, rain or snow, then you’ll want to use a thermal transfer synthetic label. This will ensure long-term label durability in these harsher conditions.

Print Speed, Darkness and Dots Per Inch (DPI)

Another important factor to consider is that specialized labels and ribbons can affect your print speeds, potentially slowing them down or speeding them up. They may also require adjustments to print darkness and DPI. Ultimately, your printer, label, and ribbon must work together to produce the right label with the appropriate durability, adhesion, and characteristics for the job. This might mean using specialized synthetic labels or other solutions to achieve the right balance.

Getting Help with Your Barcode Label Selection

As you’ve likely realized by now, barcode labels are more complex and sophisticated than they appear, especially when you require specialized thermal transfer labels that offer superior durability, adhesion, and performance for demanding applications.

But you don’t have to figure out all of this on your own. There are quick shortcuts to matching the right label and supplies to your job, starting with a free consultation with our labeling experts at SK&T.

Zebra is our label and supplies provider of choice, and our team can help you quickly find the right label for the job at hand. We’ll save you time by offering a fast and professional recommendation based on your requirements, our extensive knowledge of real-world applications, and Zebra’s high-quality, top-performing solutions.

For prompt answers to your questions or to schedule a free consultation at your convenience, contact SK&T today at 720-851-9108 or email us.