Why Do My Labels Keep Jamming?
Troubleshooting the Most Common Causes
Label jams are annoying. They waste time, mess up your workflow, and usually happen when you're in the middle of something important. The good news? Most jams have a simple cause, and once you know what to look for, they're easy to fix…
You might be using the wrong labels
Not all labels are the same. If your labels aren't made for your specific printer, you're probably going to run into problems. For example, thermal transfer printers need ribbon-compatible labels, while direct thermal printers don’t use ribbons at all. Using the wrong kind can throw off the feed and cause jams.
And don’t forget about label quality. Cheaper labels might have uneven liners or too much adhesive, which can gum up your printer and cause misfeeds. It’s not worth the hassle. Stick with labels that are designed for your printer and your application.
Need help finding the right ones? We’ve got you covered with a HUGE selection of custom and stock labels!
The labels might not be loaded correctly
It sounds basic, but loading labels the wrong way is one of the most common causes of jamming. Even a slight misalignment can cause the printer to pull the label crooked or fail to detect the gaps between them.
Check these things first:
Are the media guides snug but not too tight?
Is the roll facing the right way?
Are the sensors lined up where they should be?
If anything looks off, reload the roll and make sure everything is straight and secure. Each printer has its own loading method, so refer to your printer’s guide if you’re not sure.
The printer probably needs a cleaning
Label printers get dirty fast. Dust, adhesive residue, and label fragments build up inside the printer, especially if you're printing in a warehouse or dusty environment. That buildup can cause labels to stick, misfeed, or jam entirely.
Make it a habit to clean the printhead, platen roller, and sensors. Don’t use random cleaning supplies either. Use cleaning pens or wipes made for thermal printers to avoid damage.
Need cleaning supplies? We have them in stock.
Something might be worn out
Over time, parts like the platen roller or printhead wear down. If you're noticing jams more often and cleaning isn’t helping, take a closer look.
A worn platen roller might look smooth or flat and won’t grip the labels properly.
A scratched or dirty printhead can affect the way labels feed and print.
These parts are easy to replace and should be checked regularly if you're running lots of labels every day.
Your printer settings could be off
Sometimes the issue isn’t physical. If your printer’s settings don’t match the type or size of label you're using, it can cause the printer to misread the media and jam.
Check out this example of manual calibration on the Zebra ZT510B
Look at things like:
Label size
Media type
Sensor mode
Print speed
Most printers have an auto-calibration option that adjusts settings automatically. If you haven’t used that in a while, it’s worth trying.
FAQ: Why Do Labels Keep Jamming?
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It depends on your printer model. Thermal transfer printers need ribbon-compatible labels. Direct thermal printers don’t. If you’re unsure, reach out and we’ll help you match the right supplies.
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At least once a week, or every time you load a new roll if you’re printing daily. Regular cleanings go a long way toward preventing jams.
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Yes. Labels that have been sitting around for a while may curl, dry out, or lose adhesive, which can cause feeding issues.
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This usually means something’s off with the sensors or the media calibration. Run a calibration and make sure everything is loaded properly.
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We’ve got resources and support for Zebra, TSC, SATO, Honeywell, and more. If you need help, just reach out or check our support page for your model.
Have questions about your printer or labels? We’re here to help.
Have questions, and you just can’t seem to stop those pesky jams? Maybe it’s time for some expert help or a new printer… Fill out the quick form below or contact us here, and one of our experts will help you!