Can an Inkjet Label Printer Replace a Thermal Printer?
The Basic Differences
Thermal printers use a system of transferring heat onto heat-activated label material called direct thermal, or with the use of a ribbon, (wax or resin), called thermal transfer. This transfer of heat either on the surface of the label or through the ribbon, creates the image. This is the most popular and widely used method in the world today to print labels. This combination replaced the slower laser printer and dot matrix printers from the later part of the 20th century. Thermal printing is the fastest and lowest cost method today, for barcode labeling and wide variety of variable imaged labels.
Inkjet technology, (full color printing), has improved greatly in the last 5 years and is emerging as a alternate to thermal. Inkjet printing has become faster than earlier versions and offers a very durable imprint. So durable it holds up to liquids and chemicals. The greatest advantage is the eye catching color. Black and white labels are informational only. Color creates an opportunity to advertise in a whole new way. Epson, VIP, Afinia and other inkjet technology printers uses light-fast, UV, waterproof inks to create micro dots of ink onto roll label material that is very durable and now comes in matte and gloss finishes.
One other advantage for inkjet is the high resolution. These printers can print durable, very small fonts and high quality graphics. This is important in any industry where instructions that cannot be read, or icons that are not readable, could lead to law suits. Industries like Pharma, Healthcare, Food, (ingredients), and Chemical have all adopted high speed ink jet printing, from Epson Colorworks, VIP and Afinia.
Price of Inkjet?
Ink jet label material and the ink jet cartridges are about 5 to 7x higher in cost than thermal transfer or direct thermal - if comparing to a standard shipping label or UPC label. The advantage is to grab your customers attention with eye popping color.
If comparing to using a printer to create full color labels, ink jet can cost 5 to 10 times less. You also have the advantage of printing exactly what you want, when you want your labels. A color print manufacturer can take from 4 to 6 weeks. When compared to small batch full color label requirements between ink jet and a color print manufacturer, ink jet is the best choice.
Ink jet is ideal for product labels, GHS warning labels, hazardous or very durable small and intricate labels, and labels where you can grab your clients attention with an offer.
Basic Cost Differences: Thermal printers are designed to produce millions of labels on one printhead, at prices from 1 to 3 cents per label, on average.
Basic Cost Differences: Thermal printers are designed to produce millions of labels on one printhead, at prices from 1 to 3 cents per label, on average.
Example: 4x6 Direct Thermal, 3” core” 8” O.D.
1,000 matte label cost per label $0.017 , Synthetic $0.182 (no ribbon cost).
Example: 4x6 Epson Color Label, 2” core, 4” O.D.
950 matte label cost per label $0.41, Gloss labels $0.73 each.
Printer Pricing: Comparing the Zebra ZT411 and the Epson C6000 color printer.
Example: Entry model Zebra ZT411= $1,300, Newest Zebra ZT610 = $2,657.00.
Example: Epson ColorWorks C6000 gloss or matte models= $2,450,
ColorWorks C6500 matte or gloss, $3.325
Printer Yields: Comparing inkjet to thermal yields can be tricky. If you use direct thermal labels there is no ribbon cost. If you use thermal transfer labels this cost of the ribbon varies:
Example: Wax Ribbon 4” wide at $95/case yields 35,424 4x6 labels.
Example: Epson Ink Cartridges are $45 per color, CMYK and yields depend totally on coverage. Exact estimation can be given only directly through an Epson sales representative.
Material Concern
2021 and 2022 has made us all aware of supply chain issues, which a smart buyer will no always keep in mind. Thermal printer labels have seen a lot of price increases, but not a lot of shortages. Wax ribbons have seen some resin shortages but the supply stream has not stopped throughout 2021 or 2022, so far. The specialty production of inkjet labels has however seen very long lead times and some outages.
Thermal Printers
Loading labels and ribbon can be complicated
Resolution of labels can be 230, 300 or 600 dpi max
Must adjust heat, pressure, speed and media
Careful care of printhead must be taken
Label durability levels depend on label material
They can last from 2 to 8 weeks plus, considered
Water-resistant
Compatible with PC only using ZPL language
Inkjet Printers
Front load drop in label roll and feed end into print plot
Always a 1200 resolution
Always creates consistent color
Nozzle verification insures consistent prints
The labels can be used for many GHS hazardous requirements
and are considered waterproof
Water-resistant
Plug and play using ZPL language. Also Macintosh compatible
Thermal Printing If your business prints shipping, internal, pricing or data labels for indoor use and or short exposures to weather in large or small amounts, you need a thermal printer. If you desire color indicators, logos or warning on your labels, simply have them pre-printed in yearly usage amounts and use the same label format.
Color Inkjet Printing Color thermal inkjet has found a home with many new start-up businesses. Business’s that produce multiple varieties, flavors or brands of products and require colorful product labels fid inkjet to be a great alternative. Even established businesses with test product launches or smaller specialty runs find uses for inkjet printers. Another great demand we see is in the chemical and pharmaceutical industry. Many large companies have converted their pre-printed red GHS labels over to custom color on drum labels, freezer applications and durable shipping labels.
In short, there’s a space for each technology, don’t compare them, but determine which fits your needs the best.
Zebra ZT411 Sereis Thermal Printers
Epson ColorWorks C6000 Series