Barcode label printers are specialized printers designed specifically for printing barcodes on various materials like labels, cards, wristbands, ribbons, and more. Unlike regular office printers, barcode printers use technologies optimized for producing the very fine details required for machine-readable barcodes.
The most common technologies used in barcode label printer today include:
- Thermal transfer – Uses a ribbon to transfer ink onto the media
- Direct thermal – Prints onto thermally sensitive media
- Dot matrix – Impact printing with a printhead and ink ribbon
- Inkjet – Sprays ink droplets onto the media
- Laser – Uses a laser beam and toner to print barcodes
Barcode printers allow businesses to create and print custom barcoded labels, documents, and more on demand. This provides significant advantages for inventory management, product identification, supply chain tracking and more.
A Brief History of Barcode Printing Technology
The first primitive barcode systems were developed in the 1930s but saw limited use. It wasn’t until the 1970s that the Universal Product Code (UPC) system was adopted by retailers and consumer goods companies. This drove the need for affordable and reliable barcode printers.
Early adoption was slow due to the high costs and limited capabilities of barcode printers in the 1970s and 80s. The first models were based on modified daisy wheel or dot matrix technology. This made them large, expensive, noisy and slow.
The introduction of thermal transfer and direct thermal printing in the late 80s paved the way for cheaper, faster, smaller barcode printers. Adoption accelerated through the 90s as these new thermal printers could print high-quality barcodes on demand.
Today, thermal transfer and direct thermal printers dominate the barcode printer market. Advancements like improved printheads, connectivity options, and printing software have made barcode printing an indispensable technology for businesses worldwide.
Key Components of Modern Barcode Printers
Printheads
The printhead is the heart of any barcode printer. For thermal printers, the printhead contains hundreds of tiny heating elements that create dots on the media by heating localized areas to high temperatures. Higher resolution printheads provide sharper, more detailed barcodes.
Most industrial barcode printers use thermal printheads capable of 203, 300 or 600 dots per inch (DPI). Thermal printheads must be kept clean and can wear out over time.
For non-thermal technologies like inkjet or dot matrix, the printhead controls the firing of ink nozzles or the impact pins respectively.
Ribbons and Consumables
Thermal transfer barcode printers require ribbons coated with wax, resin or a wax-resin blend. The ink coating is transferred to the media when heated by the printhead. Direct thermal printers don’t need ribbons since the heat activates the special thermal media.
Other consumables like label/tag media and cleaning supplies will be needed with any barcode printer. Using quality consumables ensures optimal print quality.
Software
Most barcode printers include driver software that allows configuration, monitoring and some limited label design functions. More advanced design and print management software may be needed for complex or high volume printing.
Many printers now support standalone operation, with the ability to store label formats, connect to data sources like databases, and integrate with enterprise software systems.
Key Factors When Selecting a Barcode Printer
Print Resolution
Higher print resolutions allow smaller barcode details to be reproduced, resulting in better scan rates. Industrial printers offer resolutions from 203 dpi to 600 dpi or higher. Lower resolutions like 200-300 dpi are suitable for larger barcodes.
Print Speed
Industrial barcode printers are rated by the maximum print speed in inches per second (IPS). Typical speeds range from 6 IPS for desktop printers to 14+ IPS for high speed industrial models. Consider the volume of printing needed when deciding on print speed.
Media Handling
The ability to handle flexible media types and sizes is crucial for many applications. Industrial printers offer capabilities like:
- Continuous roll feeding for printing multiple labels.
- Peel & present for automatic label dispensing
- Cutters for batched printing.
- Multiple input trays for label/tag switching
Barcode Symbologies
The printer should support all the major 1D and 2D barcode symbologies required for the application, such as:
- UPC and EAN for retail
- Code 128, Code 39 for logistics
- Data Matrix, QR Codes for small item marking
Most industrial barcode printers support a wide range of symbologies.
Connectivity
Standard interfaces like USB, Ethernet and serial ports allow flexible printer connectivity. Wireless networking, Bluetooth and WiFi Direct provide cable-free convenience. Some printers also allow printing from mobile devices over the internet.
Software and Drivers
Ease of integration and compatibility with operating systems, databases and enterprise software is enabled through the printer’s drivers and software tools.
Native drivers should be available for Windows, Linux/Unix, SAP environments, etc. Software tools for design, configuration and print management are a plus.
Budget
Of course, the printer must fit within budget constraints. Desktop barcode printers can be under $500, while industrial/commercial models range from $1500 to $5000+. Match the printer capabilities and amenities to actual needs, while keeping lifecycle costs in mind.
Thermal Transfer vs Direct Thermal Printing
Thermal transfer and direct thermal printers make up over 90% of the barcode printer market. Both technologies offer digital, on-demand printing of barcodes and labels. But they differ in how the barcodes are formed on the media.
How Thermal Transfer Printing Works
Thermal transfer printers use a ribbon coated with wax, resin or wax-resin ink blends. When the printhead heats up, it melts the ink coating and fuses it to the media below to create the printed image.
Once the ink on the ribbon is depleted, the ribbon has to be replaced. The media does not need to be thermally sensitive.
Advantages of Thermal Transfer Printing
- Works on plain paper or synthetic labels, cards, tags etc.
- Produces highly durable printout with abrasion/chemical resistance.
- Yields excellent print quality for small text, barcodes.
- Ideal for strict quality control or compliance labeling applications.
Disadvantages of Thermal Transfer
- Consumable ribbons add to operating costs.
- Used ribbons have to be disposed of.
- Not well suited for very high volume printing.
How Direct Thermal Printing Works
Direct thermal printers use thermally sensitive media that turns black when heated. The printhead heats the media to form the text, graphics or barcodes. No ribbon is required.
Advantages of Direct Thermal Printing
- Lower consumable costs since ribbons are not needed.
- Faster print speeds possible since no ribbon has to be synchronized.
- Suitable for very high volume printing.
- Compact footprint since no ribbon storage is required.
Disadvantages of Direct Thermal
- Thermally sensitive media is required
- Printout can fade when exposed to heat, sunlight or chemical vapors
- Not recommended for archival or long term applications
When to Use Each Method
If print durability and quality are critical, thermal transfer printing is preferred. In cost-sensitive, high volume printing applications, direct thermal excels.
Consider the barcode application, media type, print volume and ambient conditions when deciding between thermal transfer and direct thermal barcode printers.
Top Barcode Printer Manufacturers
The global barcode printer market is dominated by just a few major players who produce both thermal transfer and direct thermal models.
Zebra Technologies
Founded in 1969, Zebra is the undisputed market leader in on-demand barcode printing. Their extensive range covers everything from small desktop label printers to high speed industrial production printing systems.
Notable Zebra models include the ZT230 entry level industrial printer, the mid-range ZT420, and the high performance Xi series.
Honeywell
Honeywell is a diversified technology company that offers barcode printers through their Honeywell Scanning & Mobility division. Models like the PC42t (thermal transfer) and PC43d (direct thermal) deliver solid performance across many industries.
SATO
SATO is a Japanese company specializing in auto-ID and labeling technologies. Their CL4NX thermal transfer and CT4 thermal direct printers combine high speeds, quality and durability for demanding environments.
iDPRT
iDPRT stands as a leading barcode printer manufacturer in China, under the umbrella of HPRT, with a focus on Automatic Identification and Data Capture (AIDC) products. This brand distinguishes itself by offering a more varied and comprehensive product lineup compared to other barcode printer brands. Additionally, iDPRT excels in providing barcode printers with an exceptional cost-performance ratio, designed to be versatile enough to cater to the needs of various industries. Among their offerings, the SP410 thermal barcode label printer is notable.
Toshiba TEC
Toshiba TEC provides thermal barcode and label printers through their TEC subsidiary. The B-EX series offers versatile, easy to use industrial printing.
Epson
Epson’s ColorWorks C7500 provides on-demand color label printing, while their Industrial Division offers fast monochrome thermal transfer and direct thermal models like the ColorWorks C7500.
Printronix
Printronix is focused on heavy duty industrial and supply chain printing applications. Models like the P8000 thermal transfer printer are designed for 24/7 operation at conveyor line speeds.
There are several other niche players and new entrants in the market, but Zebra, SATO, Honeywell and Toshiba TEC dominate the mainstream industrial/commercial barcode printer space.
Major Applications and Industries Using Barcode Printers
Thanks to their versatility, speed and reliability, barcode printers are ubiquitous across many industries.
Retail and Inventory Management
Retail was the earliest adopter of barcodes for pricing, checkout, inventory control and supply chain management. Barcode printers produce shelf tags, product labels, receipts, coupons and more.
Healthcare and Pharmaceuticals
Barcodes improve accuracy and patient safety in samples tracking, medical records, asset management, medication labeling and other healthcare applications. Special validation and compliance rules apply.
Transportation and Logistics
Airlines, postal services, freight carriers and warehouses rely on barcode printers for tracking packages, pallets, containers and other items through the supply chain.
Manufacturing and Warehousing
Manufacturers use barcodes for work in progress tracking, product identification and production control. Warehouses use them to label and sort items.
Government and Security Applications
Government agencies use barcoded IDs/access cards, evidence tracking labels, military supply chain tagging and more. Strict security protocols must be followed.
These are just some examples of the versatile applications and massive adoption of barcode printing across industries.
Tips for Barcode Printing Success
Here are some tips for optimizing barcode print quality while avoiding common pitfalls:
Choose the Right Barcode Symbology
Select a symbology that has the density to encode the needed data but avoids unnecessary complexity. Symbologies like Code 128, GS1-128, or Data Matrix are good baseline choices.
Optimize Barcode Size and Clarity
The barcode should be large enough for easy scanning. Thermal printers yield sharper barcodes at lower dpi settings. Use human readable text below for clarity.
Test Quality and Scannability
Use a verifier to regularly test print quality per ISO standards. Check that barcodes scan accurately under typical conditions.
Mind the Orientation and Placement
Avoid wrapping barcodes around curves or edges that can distort them. Keep adequate “quiet zone” margins around barcodes.
Maintain the Printheads
Clean the printheads regularly to prevent debris buildup. Replace worn printheads to maintain print quality.
Proper barcode printing comes down to choosing the right symbology, size, materials and printer. Testing and validating quality is also essential for robust operation.
The Future of Barcode Printing Technology
Barcode printing will continue evolving alongside emerging technologies. Some key trends to expect:
2D and QR Code Growth
2D symbologies like QR Codes, Data Matrix and Aztec Code enable more data density in a smaller footprint. This allows smaller barcodes ideal for items like electronics, medical devices and jewelry.
Mobile and Cloud Printing
More printers will have wireless connectivity for printing from any location. Cloud based monitoring and management will leverage IoT technologies.
RFID Smart Labels
RFID tags and readers complement barcodes with two-way communication and non line of sight scanning. Printers will increasingly integrate RFID encoding.
Sustainable Technology
Expect continued focus on energy efficiency and eco-friendly materials like plant-based or recyclable plastics in printer and media design.
While core thermal printing will remain prominent, barcode printers will offer growing versatility and connectivity while embedding in the new smart factory ecosystem.
Conclusion
Barcode printing revolutionized retail and supply chain management by bringing automated product identification and data capture. Today these specialized printers are indispensable across many industries including warehousing, manufacturing, healthcare, transportation and more.
Choosing the right barcode printer involves understanding key technologies like thermal transfer and direct thermal printing. The printer must also match needs in print speed, quality, media handling, connectivity and software capabilities. Leading vendors include Zebra, Honeywell, SATO and others.
With the right barcode printing strategies, labels and documents can be produced on demand for more efficiency and accuracy in business processes. Emerging trends like 2D barcodes, RFID smart labels, web printing and green technologies will influence future generations of these mission-critical identification and tracking devices.
Frequently Asked Questions
What are the main types of barcode printers?
The most common types are thermal transfer, direct thermal, inkjet, laser and dot matrix. Thermal transfer and direct thermal make up over 90% of barcode printers.
Should I choose thermal transfer or direct thermal?
Thermal transfer offers better durability and quality while direct thermal has lower costs. Choice depends on application, volume, and media factors.
What kind of interfaces do barcode printers support?
Common connectivity options include USB, serial, Ethernet and Bluetooth. Many industrial printers also support wireless and web printing capabilities.
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What barcode symbologies should my printer support?
Common 1D symbologies include Code 39, Code 128, UPC/EAN. For 2D, look for PDF417, QR Code, Data Matrix support.
How fast do barcode printers print?
Print speeds range from under 4 inches per second for desktop models to over 14 inches per second for high volume industrial printers
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