Labels are used everywhere in our daily lives: price labels, shipping labels, wine labels, bottle labels, cosmetic labels, nutrition labels, and many more. Among them, direct thermal labels are one of the most popular label types due to their wide applicability, cost-effectiveness, and ribbon-free printing process, especially for short-term and bulk labeling needs.
Here in this article, we will walk you through how to choose the best direct thermal labels for your business, especially if you are new to the industry.
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What Are Direct Thermal Labels?
Direct thermal labels, or DT labels, are heat-sensitive labels with a coating on the label surface. When it passes under a heated printhead, the coating melts at high temperature and turns black, producing the printed text, image, and barcode. All this can be completed in milliseconds without the need for ink, toner, or ribbons.
To better understand DT labels, let’s break down their multi-layer architecture. Direct thermal labels are made of the following layers, which you can see with your eyes:
- Facestock: This is the top tangible layer of the label. As the outermost layer of the label, you can see and feel it on your mailers and containers. And the chemical coating is implemented on the facestock.
- Adhesive: This is the middle layer, and as the name suggests, it acts as an adhesive between the facestock and the surface it is being applied to.
- Base paper: This is also known as liner and is the bottom layer that enables the label to have a seamless feed through the printer. Often considered a waste, the quality of the liner is quite crucial to avoid printing issues like jamming and curling.
Some thermal direct labels have an optional top coat above the facestock. It is added to special packages when an extra layer of protection is needed. These are added in situations where the label needs to be protected from unfriendly conditions such as moisture, scratches, and chemical exposure.
The other popular thermal label type is thermal transfer label. Check out the differences between Direct thermal labels and Thermal transfer labels.
What Are the Different Types of Direct Thermal Labels?
Depending on the different types of facestock, adhesive, and base paper, DT labels can be categorized into many types.
1. Top Coated Thermal Labels
These top-coated labels have a special coating treatment over the facestock that protects the labels from resistances like oil, moisture, scratches, and more.
2. Eco Grade Therma Labels
These are economical direct thermal labels ideal for short-term labeling usage like barcodes, D2C shipping parcels, and receipts. They are usually not resistant to scratches and water.
3. Thermal Synthetic Labels
These are premium quality thermal labels that offer high durability to resistances like oil and moisture. They are made of polypropylene or polyethylene, making them a suitable choice for long-term inventory like cold storage.
4. Permanent labels
This is the most common type of DT labels, and as the name suggests, they stay on the applied surface for a long-time (ideally permanent). They are made with hot-melt adhesive during production. Upon peeling, these labels get damaged; therefore, they are a wise choice for short-term usage scenarios like shipping, labeling perishable items, and more.
5. Removable labels
As the name suggests, these are thermal labels that can be easily removed from the applied surface. Unlike the permanent label, they stick firmly when applied and leave the surface without getting torn. They are usually made with water-grade or oil-grade adhesive during manufacturing.
6. Freezer-grade labels
These are heat-sensitive labels that come with a strong adhesive layer. The adhesive layer can bear rigorous temperature ranges that can be as low as -40°F or all the way up to 120°F. Freezer-grade thermal labels are an ideal choice for cold storage, frozen chicken, and medical business owners.
7. High-Tack / Strong Adhesive Labels
Thermal direct labels that have high initial tack are known as high-tack or strong adhesive labels. This means these DT labels stick to the surface when coming in contact with the application surface without the need for hard pressing. They are used for long-distance shipping and the logistics industry.
8. Linerless DT labels
These types of DT labels possess the eco-friendly and sustainability capabilities of the linerless labels. Linerless direct thermal labels do not have a backing paper and peel away, leaving zero waste behind. Also, they are quite economical in the long run because they offer approximately over 50% more labels per.
Are All the Direct Thermal Labels the Same?
The straight answer is No. There is no one-size-fits-all in the labeling industry. You should really consider overall factors such as application, printing, temperature, the object being stuck, and other factors to choose the right DT labels.
Here are some of the common scenarios for your reference.
| Industry | Label Type | Features |
|---|---|---|
| Supermarket / Retail | Eco-grade Labels | Price and weight scale labels, not resistant to water and scratches |
| Shipping / Logistics | Permanent labels | Permanent adhesion for long-distance shipping |
| Frozen Food / Cold Storage | Freeze-grade Labels | Dedicated freezing grade adhesion for permanent sticking |
| Chemical / Industrial | Synthetic Labels | Synthetic film labels, resistant to water, chemicals, and harsh conditions |
| E-commerce / Warehouse | Top-coated Labels | Top-coated labels, resistant to water, scratches, and solvents |
| Reusable Packaging | Removable Labels | Removable labels for multiple uses, leaving no residue on the objects |
| Airline Baggage Tag | Synthetic Labels | Soft and strong labels, resistant to tearing, with extra-strong adhesion |
What Are the Common Sizes of Direct Thermal Labels?
The manufacturing of thermal labels is a complex process, even though the product seems simple. Basically, it involves laminating different facestock, adhesive, and liner types based on the intended use, followed by further die-cutting and slitting into custom shapes and sizes per the client’s specifications.
Thermal labels come in various sizes; different industries, such as retail, shipping, logistics, and healthcare, use different label sizes. However, there are still common sizes widely used across different industries.
| 30 x 20 mm | 58 x 38 mm | 100 x 100 mm | 102 x 76 mm |
| 38 x 25 mm | 60 x 40 mm | 101.6 x 76.2 mm | 102 x 102 mm |
| 40 x 30 mm | 75 x 50 mm | 101.6 x 152.4 mm | 102 x 152 mm |
| 50 x 25 mm | 100 x 50 mm | 102 x 38 mm | 102 x 175 mm |
Where to Buy: Order Premium Thermal Labels from Panda Paper Roll
With so many label options and sizes available, finding a reliable supplier for your business’s labeling needs can be challenging. Well, your search ends at Panda Paper Roll. At Panda Paper Roll, we have one of the largest portfolios of label products, including direct thermal labels, thermal transfer labels, linerless labels, specialty labels, and many other label types. Check out our array of thermal labels manufactured in our modern factory, available for worldwide shipment, and Contact us today for a free quote for your label products.
Direct Thermal Labels Frequently Asked Questions
1. Are direct thermal labels and thermal transfer labels the same?
No, they are not the same. Thermal labels are printed in two different ways: Direct thermal labels have a special coating that turns black when heat is applied; they do not require a heated ribbon. Whereas thermal transfer labels use a heated ribbon, which comes in a variety of colors and finishes.
2. How do direct thermal labels work?
Direct thermal labels have a specially coated layer that is sensitive to heat. When this layer comes into contact with a heated thermal printhead, the coated layer gets activated. The sticker is printed and darkens on the surface, strategically removing the need for ribbons, ink, and toner.
3. What is the cost of using direct thermal in the long run?
In the long-run, DT labels are quite cost-effective because they operate on a lower operational budget. Because no inks or ribbons are needed, you don’t pay for consumables. Meanwhile, the downtime is minimal because there are fewer parts to be maintained. However, the paper makes direct contact with the printhead, which may require frequent replacement.
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