“The global airline boarding pass market isn’t some tiny niche. In fact, it was valued at a massive $4.8 billion industry in 2023 that’s racing toward $9.1 billion by 2032. That’s a healthy 7.5% yearly growth rate, sustained over a decade.”
Although digital boarding passes hold a 41% market share within the global boarding pass market, and that number continues to grow with the evolution of technology like self-service kiosks and mobile applications. Traditional paper boarding passes still account for a large part of the market, as they remain a reliable fallback for maintaining a smooth aviation experience.
Whether you are an airline, station, or travel company, if you want to explore more about this humble but important piece of paper, or you’re looking for a trusted boarding pass paper manufacturer, this comprehensive guide is for you. Please keep reading.
Quick Jump Links:
- What Is A Boarding Pass Paper?
- Differences Between A Boarding Pass Paper and Regular Thermal Paper?
- What Are the Specifications of A Paper Boarding Pass?
- What Are the Common Boarding Pass Paper Sizes?
- What to Look for When You Purchase Boarding Pass Papers?
- Choose Panda Paper Roll’s Premium Boarding Pass Paper
What Is A Paper Boarding Pass?
A sample paper boarding pass
Unlike a digital boarding pass on your smartphone, a paper boarding pass is a physical paper cardstock printed by airlines or airports at check-in counters or self-service kiosks that gives you permission to board the plane. It contains several important pieces of information, such as the passenger’s name, flight number, departure time, boarding gate, seat assignment, and a scannable barcode or QR code.
Paper boarding passes still remain mandatory at some airports and airlines and in some countries due to differing policies and regulations. Most paper boarding passes are made from thermal paper, which is a specialty paper with an invisible coating on its surface. When printed on the dedicated thermal printer or kiosk, the printhead heats the coating on the paper, and the printed area darkens to form the text or barcodes. The process can be completed in milliseconds, and the printed text can be retained for at least 24 months, which is why thermal paper is widely used for airline boarding passes.
What’s the Difference Between A Boarding Pass Paper and Regular Thermal Paper?
You may notice that both the boarding pass and the POS receipt paper use the same thermal printing technology. But what’s the difference between them? You can find the key takeaways from the table below.
| Feature | Boarding Pass Paper | POS Thermal Paper |
|---|---|---|
| Paper Weight | 110 – 200 gsm | 48 – 80 gsm |
| Application | Airline boarding passes and tickets | POS transaction receipts, etc |
| Material | Enhanced thermal coating with protective layers | General thermal coating |
| Durability | Thick paper, long-lasting printing | Soft paper, less durable, curls easily |
| Print Quality | High-resolution | Standard quality |
| Special Features | IATA compliance, watermark, perforation, etc. | No features, just plain paper |
| Cost | Higher | Lower |
In conclusion, boarding pass paper is thicker, more durable, and of a higher grade; it’s the preferred choice for aviation purposes, while regular thermal paper serves general business needs like printing supermarket receipts, event tickets, ATM receipts, and others.
What Are the Specifications of A Paper Boarding Pass?
There are two primary features in the design of a paper boarding pass: high-quality printing and high durability – these are the DNA of it. It has to print clear text and barcodes that are easily readable and scannable at every checkpoint while withstanding frequent handling. There are also some other features and specifications included in a boarding pass paper design, which are explained below.
(Click to view full-size image)
- Material: Made from 110–200 GSM direct thermal paper or heavier cardstock with different thicknesses
- Top Coating: Top coated thermal paper with improved resistance to water, scratches, smudges, and tearing.
- Dimensions: Come in standard or custom dimensions (explained below)
- Formats: Rolls on a core or fan-folded accordion style in a stack
- Perforations: Vertical perforations for clean and easy separation.
- Die-Cutting: Custom shapes, corner radius, and other custom designs are available upon request.
- Print Resolution: High-sensitivity thermal paper with a minimum print resolution of 200 DPI, even at high-speed printing
- Printer Compatibility: Compatible with IER, VidTroniX, Epson, Zebra, and other leading airport printer manufacturers
- Printing Method: Direct thermal printing method without the use of any ink, toner, or ribbons
- Custom Pre-Printing: Custom branding, commercial advertisements, and other pre-printing on the front and reverse
- Safe Materials: BPA-free, BPS-free, and phenol-free paper materials
- IATA Compliance: Completely compliant with IATA boarding pass standards
What Are the Common Boarding Pass Paper Sizes?
Standard boarding pass dimension 203.2 x 82.55 mm
Different airlines and airports generally use different boarding pass paper sizes due to variations in printing systems, printer models, and operational environments. Yet, we still compile a table of common paper boarding pass sizes used across various customers.
| Boarding Pass Size (inches) | Boarding Pass Size (mm) |
|---|---|
| 8 x 3.25 inches | 203.2 x 82.55 mm |
| 7.375 x 3.25 inches | 187.3 x 82.55 mm |
| 8.25 × 3.25 inches | 209.5 × 82.55 mm |
| 8 x 3.125 inches | 203.2 x 79.37 mm |
| 7.375 x 3.125 inches | 187.3 x 79.37 mm |
What to Look for When You Purchase Boarding Pass Papers?
When choosing a boarding pass paper, keep an eye on these key quality factors:
- Print clarity. This is the most important factor you’ll consider. It measures how accurately the paper reproduces texts, barcodes, and QR codes, which are essential for airport scanning systems. High-quality paper produces sharp and clear barcode readability across all printing densities for smooth processing of passengers’ information.
- Paper thickness (GSM). GSM means grams per square meter, it indicates paper weight and durability. Most boarding pass papers range between 130 and 175 GSM. Higher GSM paper usually provides better durability and a premium feel.
- Scanner compatibility. Quality boarding pass paper must work reliably with major airport scanning systems, including TSA equipment, gate scanners, and mobile check-in kiosks, without causing reading errors.
- Anti-curling. Airport environments expose paper to humidity and temperature variations. Premium papers can resist curling and maintain a flat surface for reliable scanning and a professional appearance.
Additional considerations include water resistance for beverage spills, fingerprint resistance for handling, and head-cleaning properties that protect printer mechanisms during operation.
Where to Buy: Choose Premium Boarding Pass Paper from the Manufacturer
At Panda Paper Roll, we specialize in producing and supplying aviation consumables, including boarding pass paper, thermal baggage tags, and airsickness paper bags that meet airline aviation industry application specifications while delivering significant cost savings.
Our products deliver 95% of the performance of premium brands at 50-60% of the cost, providing airlines with an optimal balance of quality and value. Contact us today to discuss your boarding pass requirements, and we’ll arrange delivery directly to your headquarters or branches – anywhere in the world.
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