How to Choose the Right Label Size for Your Business

Selecting the correct label size and core type is just a matter of compatibility with your printer. It involves determining what is most suitable for your product, your workflow, and your budget.

Therefore, let us discuss this in straightforward terms and assist you in making the right choice from the outset.

What Does “Core Size” Even Mean?

Let’s start with the basics. When someone says "1" or "3" core, they’re talking about the inner diameter of the roll that your labels are wound on.

• 1" Core: Common for desktop printers (like Zebra or Rollo). Perfect for small-scale, on-the-desk setups.

• 3" Core: Meant for industrial printers, big, rugged machines built to run all day.

• Fanfold: Not on a roll at all. These are stacked labels, ideal for high-speed printing without roll changes. They sit behind or under the printer.

Why Label Size Matters

Size isn’t just about what fits the box it affects everything from how your brand looks to how readable your barcode is. For most small businesses, the go-to sweet spot is:

4” x 6” Labels

This size is the holy grail for shipping and product labeling, and here’s why:

• Big enough for all the important info

• Works perfectly with UPS, USPS, FedEx, Shopify, and Amazon shipping systems

• Fits barcodes, logos, addresses, and tracking numbers with no crowding

• Compatible with most thermal printers (desktop and industrial)

When to Use Other Label Sizes

Depending on what you’re selling or shipping, you might want to switch it up:

Label Size	Best For
2" x 1"	Small product labels, barcode stickers, jars, small boxes
4" x 2"	Shelf labels, bag seals, medium packaging
6" x 4"	Large product labels, oversized packages, compliance labels
2.25" x 1.25"	Retail price tags, small boxes, returns

Direct Thermal vs. Thermal Transfer

Before you place your label order, don’t forget your printer type:

• Direct Thermal Labels:
  Heat-sensitive, no ribbon needed. Great for short-term use like shipping labels. (And yes, 4x6 is the go-to.)

• Thermal Transfer Labels:
  Require a ribbon, but offer better durability. Perfect for product labels that need to last longer.

Choosing What’s Best for You

Here’s a simple cheat sheet:

Business Type	Recommended Label Type
E-commerce (Shopify, Etsy)	4x6 direct thermal, 1” core (desktop) or fanfold
Retail/Products	2” x 1” thermal transfer for shelf & product labels
Warehouse/Industrial	4x6 thermal transfer, 3” core rolls or fanfold
Boutique shipping	4x6 inkjet-compatible or thermal, depending on printer

Tips to Make the Right Choice

1. Know your printer: Check your printer model for compatible core size and max label width.

2. Think about your workflow: If you're printing 200+ labels a day, fanfold or 3" core labels are your best friend.

3. Choose the right adhesive: Standard permanent works for most. For refrigerated or textured surfaces, go for stronger adhesive options.

4. Don't overcomplicate it: If you’re just starting out, start with 4x6 direct thermal fanfold or 1” core rolls. Simple, effective, and budget-friendly.

Final Thoughts

• Label Size = Function

• Core Size = Printer Compatibility

• Material Type = Lifespan

Start with your needs, match it with your printer, and you are good to go.

Still confused? Don’t worry. We have tons of options at 4x6Labels, and our team is just a click away to help you pick the right fit.