Ink Jet Coding Label Printers / Bar Code Printers Custom Screen Printing Bar Coding
There are several critical issues to consider when choosing a thermal printing system that will fit your specific needs. The following checklist will assist in guiding you through the process of selecting the right labeling system for you.

1. Defining Your Application: Why do you need an on-demand labeling system? What do you need to print on your labels? How will you create your label formats? Where will your labels be printed?
2. Print Technology: Which print technology best meets your needs? (Thermal Transfer VS. Direct Thermal)
3. Connectivity Needs: Do you require a stand-alone or computer-driven printing system? If you select a computer-based printer, how will it fit within your existing computer system?
4. Media Requirements: Which label or label/ribbon combination is best for your application?
5. Printer Specifications: How should your printer be configured?
6. Verifications Requirements: What type of guidelines will you use to verify your bar codes? Will you require portable, desktop or on-line verification?
7. System Support: What Level of support and responsiveness will you need?
DEFINING YOUR APPLICATION

Understanding your labeling needs up front will simplify the process of choosing the ideal printer for the job. Consider each of the following key questions:

Why do you need an on-demand labeling system?
Will your printer be utilized for internal improvement such as capital asset management, inventory control or time and attendance reporting - OR - to meet corporate or industry mandated labeling requirements such as automotive AIAG, electronic EIA or retail UCC/UPC specifications?

What do you need to print on your labels?
Many users of thermal printing technology generate bar coded labels. However, some labeling applications never use bar codes but require high resolution printers to produce text or graphic images. Your labels may include bar codes, alphanumerics, graphics or any combination of the three.

Bar code considerations:
Bar code symbologies are grouped into two distinct categories. Linear symbologies , a combination of vertical bars and spaces of varying widths:
Linear Bar Code Symbology


Two-dimensional symbologies, which can encode large amounts of data in relatively small spaces:
Two dimensional bar code


If you'll be printing bar codes for internal use, you may have the freedom to select a symbology that suits you. But if you're printing labels to meet customer or industry specifications, you'll need to use a specified symbology. Make sure the printer you select supports the symbology you require. Additionally, if you must meet compliance labeling standards, you may require a printhead with a specific print resolution and maximum print width. For example, if you need to print UPC symbols at 100% magnification, a 152 or 304 dpi printhead is ideal; you'll be outside the specification with a 203 dpi printhead. Or, if you'll be generating labels to meet the European automotive industry's ODETTE standard, you'll require a printhead that's over 6 inches wide.
Text Considerations:
  • Determine whether you'll print small or large characters. Resolution can be a critical concern. Printers with resolutions of 300 dpi can produce images that are crisper and clearer than those produced by laser printers. These high resolution models are ideal for applications that require very small text, such as PC board labels or jewelry tags.
  • Determine if you'll need special typefaces. Some fonts are bitmapped, others are scalable. Bitmapped fonts may require less formatting time than scalable fonts and are excellent for many applications but scalable fonts allow for printing of very large, crisp text without jagged edges, which may be important if you require large bin pallet or location labels.
Graphic Considerations:
  • If you'll be printing graphics (logos, line art, gray scales or other complex images), look at resolution. Detail is enhanced as resolution is increased. So if your print requirements call for intricate graphics you'll probably want a 300 dpi printhead rather than a lower resolution printhead

How will you create your label formats?
Many printers are programmed via manufacturer-specific or printer-specific programming languages. If you don't want to take the time to master a new skill, there are literally dozens of software packages on the market that may simplify the label creation process:
  • If your printer has a Windows driver, you can create label forms using virtually any Windows program including word processing and desktop publishing software.Many software packages offer WYSIWYG "what you see is what you get" support, which enables you to view a graphic of the label on your monitor.The software may allow you to create custom graphics, logos and typestyles without the aid of a separate software package.Some software is compatible with DOS or Macintosh PC environments, other packages are designed for multi-user midrange or mainframe systems.Many will interface with existing databases.
  • Some are easier than others to master.
As you investigate the alternatives, you'll discover that functionality varies from basic to complex. If you choose to purchase a separate label creation package, test it for ease of use and confirm that it supports your symbology, connectivity and functionality requirements.

Where will your labels be printed?
In a controlled environment such as a centralized data processing area, laboratory or office, you probably won't need to worry about such factors as printer construction or internal versus external media supply or rewind. On the other hand, your printers may be located in an uncontrolled environment and subjected to temperature extremes, excessive humidity, airborne particulates and other harsh elements. If this is the case, a rugged steel-cased cabinet that shields the printhead, electronics and media may be advisable.

PRINT TECHNOLOGY

Which Print Technology Best Meets Your Requirements?
Thermal technology includes direct thermal and thermal transfer printers. Many support both direct and transfer operation. These clean, quiet, versatile printers have become commonplace in the widest range of applications and environments. Direct thermal and thermal transfer printers offer a variety of performance, functionality and features to meet varied needs.

Thermal Transfer Technology:
  • Creates images by using heat to transfer ink from a ribbon to a label
  • Uses a wide selection of paper and synthetic label materials with matched ribbons, including colored ribbons
  • Produces permanent images with unparalleled staying power for long term archival applications
  • Generates bar codes that are scannable in both infrared and visible light spectrum.
Direct Thermal Technology:
  • Applies the same basic process but does not require a ribbon
  • Uses heat-sensitive label materials, typically paper stocks
  • Produces images that are sensitive to ultra-violet light, heat and many chemicals
  • Is ideal for short-lived applications, such as food processing, shipping or clinical laboratory sample tracking
CONNECTIVITY NEEDS

Do you require a stand-alone or computer-driven printing system?
Many thermal labeling systems do not support stand-alone operation and must interface with a computer. Be mindful of each system's advantages and limitations.
Stand-alone printing may be preferable and perhaps most cost-effective in a limited range of situations. Some users prefer not to tie up a computer and will install stand-alone systems for simple applications, such as compliance labeling. Also, a stand-alone printer may be used in an industrial environment that is too harsh for a typical computer.

A computer-based printer must be linked to a host, such as a PC or mainframe system. With the right program, you can extract variable information from an on-line database, such as purchase order number, weight or serial number, and encode the data in a bar code. You also can report data back to the computer after a label prints, perhaps to prompt an invoice when an order ships, or to issue a restocking order when inventory levels reach a certain point. This configuration may require more effort to install. However, it can minimize operator intervention and manual data entry requirements and ensure that the data printed on a label is accurate and timely.

If you select a computer-based printer, how will it fit within your existing computer system?
A computer-driven system may require a specific communications interface. For example, you'll need a twinax interface or an external protocol converter to connect your printer to an IBM AS/400. When evaluating printers, be aware that some manufacturers offer interfaces that others don't. Remember, your printer must be compatible with your host computing environment.
MEDIA REQUIREMENTS

The quality and durability of the printed image is the most important element of your system. Don't overlook supplies when outlining your requirements. Using the wrong label or ribbon can literally mean the difference between success and failure.

Which label or label/ribbon combination is best for your application?
Literally hundreds of combinations exist. Facestocks, adhesives and ribbons must be carefully matched and tested to optimize both printer and label performance. Every printed label must withstand the environment of your application and remain both legible and scannable during its entire life cycle, which could range from minutes to years. In making your selection, take into account the following key points:
CHOOSE THE RIGHT FACESTOCK
Consider your usage environment and your requirements for label life and image stability. The label you place on your product or package may be subjected to all types of abuse. Facestock materials fall within two broad classifications:
  • Paper is the most common of all direct thermal and thermal transfer stocks and is the least expensive. It can be coated or uncoated to meet various requirements for print quality and cost.
  • Synthetics include, but are not limited to, polyester, vinyl and mylar. These may be better suited than paper for applications where the label is subjected to excessive abrasion, heat, ultra-violet light, chemicals or other potentially destructive elements.
SELECT THE RIGHT ADHESIVE
A variety of general purpose and specialty options are available to meet a wide range of application requirements. Choose an adhesive formulation that is matched to your needs.
  • Some adhesives are permanent and will keep a label in place even with exposure to temperature extremes, high humidity, chemical immersion or outdoor use. Others can be easily removed from any labeling surface without leaving a residue. Still others are tamper-evident and will not come off in one piece if removal is attempted.
  • Be aware that some labeling surfaces are particularly difficult to label. Specific adhesive formulations will be needed for certain hard-to-label surfaces such as wood, recycled corrugate, refrigerated materials and small curved objects.
MATCH THE RIBBON TO YOUR FACESTOCK AND APPLICATION.
Thermal transfer ribbons come in a variety of lengths ranging from 300 meters to 600 meters and are available in three basic formulations:
  • Wax-based ribbons, popular and low in cost, are used with both paper and synthetic facestocks to produce high-quality images that are durable enough for most applications. However, the images will smear or scratch off if subjected to abrasion or heat.Resin-based ribbons produce very high quality images on both paper and synthetic materials and are resistant to smudging, abrasion, many chemicals and harsh environments. For example, when matched with certain synthetic stocks, some resin inks can withstand temperature in excess of 1000 degrees Fahrenheit.
  • Wax/Resin combination ribbons combine the advantages of both, offering higher durability than wax at a lower cost than resin based products.
Regardless of your application, you must first define the item to be labeled, the required label life and the usage environment. Once you have found a possible solution, test and re-test printed labels in your application to ensure continued success.

PRINTER SPECIFICATIONS

How Should Your Printer Be Configured?
With all of the options available, it's easy to get confused and purchase capabilities that aren't required for your application. That's a mistake you won't want to make because system costs typically increased as you add options and functionality. Here are some choices you'll need to consider when choosing a printer:
  • Print Speed: This can ranger from 1-12 inches per second (ips). Throughput, a combination of print speed plus formatting time, is equally important.
  • Printhead Resolution: Commonly from 100 dpi to 300 dpi.
  • Memory: From 256K to 8Mb or more.
  • Special media handling: Internal or external rewind, peel and present, media cutters, ribbon savers.
  • Font Offerings: Stored on memory cards, EPROMs or cartridges.
  • Communication Interfaces: Serial, parallel, coax, twinax or other.
When choosing your printer, understand just exactly what you'll need to produce the correct output. You may determine that your application requires everything listed above, or you may find that your application only requires a 2 ips printer with 256K of memory.
VERIFICATION REQUIREMENTS

Simply stated, verification is the bridge between bar code printing and scanning. Verifiers can decode a symbol, measure key characteristics and grade the quality of the printed symbol to ensure that a bar code is in-spec and that it will read every time.

What type of guidelines will you use to verify your bar codes?
There are several ways to measure, grade and report bar code scannability and print quality:
  • Traditional guidelines measure bar and space dimensions, print contrast and encodation.
  • ANSI guidelines measure edge determination, minimum reflectance, symbol contrast, minimum edge contrast, modulation, defects, decode and decodability.
  • Scannability Trend Index (STI) provides a report on print quality and scannability. The diagnostic data can help you decide if a symbol can be used in your system and, if necessary, can help you correct printing problems.
When specifying verification equipment, remember that a nonreadable bar code is not just an inconvenience. It's a potentially costly expense, particularly if you're printing your labels for compliance applications. A verifier that offers both Traditional and ANSI guidelines can be used to make sure you'll meet compliance standards with every label you print.

Will you require portable, desktop or on-line verification?
  • Portable and desktop units can be pen-based or non-contact laser scanner based and are designed for hand-held operation. They can be used to verify symbols as they are printed or to verify bar codes that have already been applied. Although pen-based verified can be used for a variety of applications, non-contact laser units are preferred when verifying symbols on rough, curved and other irregularly shaped surfaces.
  • On-line verifiers automatically verify every bar code you print to guarantee 100% accountability. Mounted on the front of or within a printer, an on-line unit will examine every symbol as it is printed and stop printer operation or trigger an alarm if a bar code is unscannable or out-of-spec.
SYSTEM SUPPORT

Support can be offered by manufacturers through depot-level service, or locally through distributors or third-party service organizations.

What level of support and responsiveness will you need?
In assessing your support requirements, determine the importance of:
  • On-site service
  • Emergency equipment swaps or rentals
  • Guaranteed response time
  • Telephone technical assistance hotlines
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