3 Types of Direct Thermal Labels

Direct thermal labels are very important in sectors such as retail, logistics, healthcare, and shipping. They operate without the need for ink or toner, rendering them straightforward and economical.

The three main options include 1" core rolls, 3" core rolls, and fanfold labels. Each option possess distinct characteristics and applications.

1" Core Direct Thermal Labels

These labels are wound on a small cardboard core with a 1-inch diameter. They are the most common choice for desktop thermal printers.

Key points

• Compatible with compact desktop printers like Zebra, Rollo, and DYMO
• Ideal for small to medium shipping operations
• Easy to handle and store in limited spaces
• Best for 4x6 shipping labels, retail tags, or barcode labels

Use them when:
You run a small business, print a moderate volume of labels daily, and want rolls that fit neatly into desktop printers.

3" Core Direct Thermal Labels

These labels use a 3-inch core and are typically larger rolls. They work best with industrial thermal printers designed for higher throughput.

Key points

• Designed for large, heavy-duty printers. 
• Hold more labels per roll, reducing changeover times
• Suitable for high-volume warehouses, manufacturing, and distribution centers
• More cost-efficient for bulk operations

Use them when:
You operate a warehouse or fulfillment center with continuous label printing needs. They help reduce downtime and keep workflows moving.

Fanfold Direct Thermal Labels

Fanfold labels are stacked in a box rather than wound on a roll. They are fed into a printer through the back or bottom, depending on the model.

Key points

• Packaged flat with perforations for easy separation.
• Take up less storage space compared to rolls
• Reduce printer downtime since boxes hold more labels
• Prevents label curling often seen with rolls

Use them when:
You want long print runs without interruptions, have limited storage, or need labels that stay flat after printing.

How to Choose the Right Option

Selecting the right label type depends on your printer and your workload.

• Choose 1" core rolls for desktop printers and low to medium print volumes.
• Choose 3" core rolls for industrial printers and high-volume operations.
• Choose fanfold labels if you want flat labels, large quantities per box, and reduced storage needs.

Final Thoughts

For small business operations, a 1" core is typically sufficient. However, for more intensive usage, a 3" core can be more economical and time-saving. If you favor flat, bulk labels, opting for fanfold is a wise decision.

When purchasing labels, ensure you verify printer compatibility and ensure that the label size aligns with your business requirements. At 4x6labels, we have all three options tailored for shipping, retail, and warehouse applications.