Direct Thermal vs Thermal Transfer Labels: What’s the Difference?

• Accurate labels are the foundation of the economy
• Thermal labels are the most cost-effective way to ship or store
• Direct thermal labels are cheaper to print
• Thermal transfer labels are more durable

In the US, around 67 million e-commerce parcels are delivered every day. That is over 24 billion parcels per year, or 1,615 per second. 

Most of these parcels contain the items that were ordered, and they are delivered to the right addresses on time. And that all comes down to labels.

Labels are everywhere. They are used in production, storage, shipping, sorting, packing, quality control, and everything in between. 

Labels Everywhere

Labels are the glue that holds the economy together, and the grease that allows things to be moved, made, stored, or located and shipped as needed. Anyone who wants to ship anything gets to decide between thermal transfer labels vs direct thermal labels.

The attributes of labels

When so many labels are used, and they are so crucial to the efficient operation of the economy and society as a whole, they have to have some key attributes:

• They must be cheap to make and apply
• Labels must be printed quickly
• The printing must be accurate and legible
• Each label must remain usable for as long as its purpose requires

There are only two types of such bulk labels with these attributes, and companies have to decide whether to use direct thermal or thermal transfer labels. Each offers particular benefits and drawbacks, and the choice can be made only based on the set of parameters that will guide its use.

How to Choose Between Thermal Transfer Labels vs Direct Thermal Labels

Thermal printing is the only way to print such labels, and there are two thermal printing technologies: direct thermal and thermal transfer printing. 

Both use a thermal printhead to heat the label surface and create a print. The difference between direct thermal and thermal transfer labels lies in the printing method.

Direct thermal label printing uses a chemically treated surface that changes color when heat is applied, while thermal transfer printing uses a neutral surface on which a thermal ribbon is placed. Heat is applied to the ribbon, which transfers the printing to the surface below. 

Direct Thermal Printing

Direct thermal printing is the simplest of the two methods because it prints directly on the surface without a ribbon.

When choosing between thermal transfer and direct thermal labels, consider what they will be used for. 

Although direct thermal labels have a long lifespan under normal conditions, prolonged exposure to heat or direct sunlight can cause the entire surface to darken or degrade the print. Abrasion can also damage the information printed on the surface. 

A practical example is a sales slip kept for warranty purposes in a warm room, which may become illegible after a few months. 

When considering direct thermal printing vs thermal transfer labels, note that the former is simpler and cheaper, and perfect for any application with a limited lifespan. These labels, when printed, are highly readable, making them ideal for event wristbands, shipping labels, patient and visitor ID in hospitals, receipts, and single-use tickets. 

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What are the benefits of direct thermal labels?

• Direct thermal printing is sharp and clear, and suitable for scanning.
• It is ideal for use with a short lifespan: suitable for shipping labels, but not for permanent product labels.
• There is no ink, toner, or ribbons that can run out, which makes them very simple to use.
• This simplicity also reduces operating costs and increases reliability.
• This also keeps maintenance costs low when printing millions of labels.
• The simplicity of the process allows single labels to be printed as cost-effectively as bulk printing.
• Users have the option to use recyclable materials.

What are the Limitations of Direct Thermal vs Thermal Transfer

• Direct thermal printing is sensitive to heat and light, including sunlight and fluorescent light.
• The paper stays chemically active after printing, and such labels may have to be treated with a UV varnish or other coatings to resist abrasion or chemical reactions.

Thermal Transfer Printing

Thermal transfer printing uses an inert surface on which a thin ribbon lined with a chemical layer is rolled. 

The printhead heats the ribbon, which melts the chemical layer onto the label surface, where it fuses with that surface. This ensures the same high-quality print on each label, regardless of the length of the print run. 

The result is a clear, crisp printed surface, often with a glossy sheen on it. The difference between thermal transfer and direct thermal printing is that the color and sharpness of the image are determined by the chemicals in the ribbon.

As long as the right print medium is used, thermal transfer printing will not be affected by heat, moisture, or strong light. It is also highly resistant to abrasion, meaning it won’t simply rub off with abrasion. 

The difference in direct thermal vs thermal transfer printing is that the former will be used in shipping a fridge, while the latter will be used for care and maintenance information of the same fridge.

Thermal transfer printing is used for identifying inventory, lab specimens, cold storage and freezers, outdoor use, and to identify and track items such as circuit boards. 

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What are the Benefits of Thermal Transfer Printing?

• Thermal transfer gives clear, high-definition printing that is very readable and produces bar and QR codes that scan very well.
• Thermal transfer printing images remain stable for a long time.
• Thermal transfer vs direct thermal printing can produce the same cost-effective batch or unique image printing.
• Although setup and running costs favor the equation of direct thermal vs transfer printing, the latter is still way more cost-effective and durable for volume printing than dot matrix or laser printing. 

What are the Downsides of Thermal Transfer Printing?

• Because they need a printing ribbon, supply costs are higher for thermal transfer vs direct thermal printing.
• The ribbon is single-pass, so printing with low ink coverage is wasteful.
• Most thermal transfer printing ribbons are difficult or impossible to recycle.
• The ribbon, printer, and printing media must be compatible; otherwise, the print will not adhere, or the media may burn or melt.