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An Informative Overview to
Bar coding in the World Around You
Part # 11878L
Barcoding & You
1. INTRODUCTION
Purpose / Intent of booklet
8. HOW TO LEARN MORE ABOUT ZEBRA BAR CODING PRINTERS & LABELING
SOLUTIONS
1 INTRODUCTION
This booklet is intended to better inform specifiers and users about automatic data collection and
the advantages of bar coding and thermal print technology utilized to facilitate this process.
Compiled by Zebra Technologies Corporation, the world leader in barcode print solutions, it
provides an objective and informative insight into this valuable technology.
While thermal print technology may not be the solution to all of your labeling problems, it is an
excellent choice for many situations, and should be well understood by every specifier or
potential user attempting to implement a barcode system.
This booklet will explain the principles of thermal print technology, discuss when its application
is most appropriate in relation to the alternative technologies available, and detail Zebra’s role in
the industry as a leading supplier of barcode printers, software and labeling supplies.
The IBM PC explosion in the early 1980’s, served as the catalyst to promote the widespread
usage and application of bar coding for automatic data collection. Over the past 20 years, bar
coding has become a virtual necessity for the collection and processing of information in a
quick and timely manner enabling companies, in every conceivable industry, to maximize and
dramatically increase their productivity and overall efficiency. Bar codes enable managers to
track information and activity as it occurs allowing their decisions to be dictated by more
concrete, current information. The traditional manual key and entry process of information
compiled on sheets of paper, by comparison, does not provide real-time data entry capability as
the data being entered usually reflects events that occurred in the past.
Yet, despite the advantages of automatic data collection via bar coding, there is still an
element of mystique and a stigma of high implementation cost associated with the technology
that intimidates many people. With a better understanding of bar coding, the requirements for
automatic data collection and its common application uses, we hope to demystify and eliminate
any apprehensions you may have and shed light on the tremendous potential for the
implementation of this technology in the world around you.
2. BARCODE CONSTRUCTION
Bar coding is a type of morse code used to encode or put information into a universally
recognized code language in the form of a bar code symbology. Encoded data can consist of a
part number, serial number, supplier number, quantity, transaction code, or other type of data.
A number of bar code standards have been developed and refined over the years into accepted
languages called symbologies. Numerous bar code trade associations, like (ANSI) American
National Standards Institute, (HIBC) Health Industry Bar Code Council and (AIAG)
Automotive Industry Action Group, have subsequently been established to regulate the use of
bar code symbologies in accordance with accepted industry standards and specifications, as
dictated by an industry.
Bar code symbologies come in two basic varieties. They can be either linear or two
dimensional in their configuration. A linear barcode symbology consists of a single row of
dark lines and white spaces of varying but specified width and height, as indicated by the
example below.
LINEAR
2-D SYMBOLOGY
The amount of data that can be encoded in a linear barcode symbology is more limited than
that of a 2-D symbology. A 2-D matrix symbology of 1 x 1inch diameter, for example, can
encode and store the entire US Constitution! Hence, the power of barcode technology in
maximizing information storage within limited space.
In addition to symbology standards set by the various trade associations, there are several
other related types of compliance standards used in manufacturing and distribution operations.
These include:
• APPLICATION STANDARDS
An application standard is a set of policies and procedures that govern an application
within an operation. Most operations have a defined set of rules to manage the material
flow and manufacturing processes in their operation. These rules can be defined as an
application standard.
• LABEL STANDARDS
Label standards (also referred to as compliance labeling within the industry) have been
created for commercial applications so trading partners can easily communicate and
conduct business transactions at a higher level of efficiency.
Depending on the specific bar code application, conformance to one or more of these
standards may be required.
3. BARCODING REQUIREMENTS
To establish a basic bar code system for automatic data collection, four primary
components are required. They are – a bar code printer, a label for item tracking, scanning
equipment for data collection and an external database for bar code data capture and relay.
Note: Zebra’s corporate strengths are based heavily on components one and two listed
here.
• Accuracy
Bar coding increases accuracy by reducing the likelihood of human errors from
manual entry or miscommunication from misread or mislabeled items. Here again,
bear in mind that print quality is of utmost importance to ensure that the scanner has
the ability to read the bar code. Without this capability the accuracy and productivity
gains of bar code technology are virtually non-existent.
• Ease-of-Use
Bar codes are easy-to-use provided the appropriate hardware and software aspects are
in place to maximize the process of automatic data collection.
• Uniform Data Collection
Diverse compliance standards and standardized bar code symbologies ensure that bar
code information is captured and relayed in a fashion that is universally understood
and accepted.
• Timely Feedback
Bar coding promotes timely feedback in that data is captured in real-time as it occurs
enabling decisions to be made from current information.
• Improved Productivity
Bar codes improve productivity in that many manual activities and tasks become
automated enabling personnel resources to be utilized in other ways to increase the
efficiencies of scale within an organization. Bar coding further enables
manufacturing processes to be monitored and tracked more closely to improve the
company’s overall quality standards.
• Increased Profitability
The increased efficiencies (e.g. improved workflows, reduction in error rates and
resultant happier customers) that bar coding promotes enables companies to save
costs and substantially improve their bottom line.
NOTE: The return on investment for an automated data collection system is typically one
year, and often substantially less.
Where was the last time you saw a barcode or witnessed an automatic data collection
transaction???
Your exposure to the world of bar coding and auto identification is likely to be more
frequent than you might think. Bar coding and automatic data collection are processes that
occur in and around us every day, without us consciously ever really thinking about it or
taking direct notice of it. Consider the convenience it provides most readily in the retail or
grocery industry to expedite one’s check-out procedure, or within the package delivery
industry to track one’s package throughout its transport cycle.
is reflected, not only, on your sales receipt, but is automatically linked to the store’s
inventory tracking system which knows to deduct the quantity of the item purchased from
the stores current level of inventory. This entire process occurs in a matter of seconds with
only minimal data entry required by the checkout person in the form of quantity purchased
– e.g. one or more.
Similarly, in a package delivery scenario, e.g. common carriers such as UPS® or FedEx®,
the barcode label enables the package to be tracked as it passes through diverse sorting
hubs en route to its ultimate destination. Throughout the package’s journey, each sorting
hub scans the package to register its receipt before passing it onward. Thus, if the
package’s arrival is ever delayed or misplaced, it can usually be tracked by its bar code
tracking number to the exact point in the process where it may have stalled.
In addition to the retail and packaging industry, barcode data collection is used in a variety
of industries, including but not limited to manufacturing, healthcare and automotive.
Generally any industry or company can utilize bar coding to track and improve their current
processes and operations. Some of the most common bar code applications referenced in
the industry are:
• Work-in-Process
Work-in-process labeling is frequently used in manufacturing facilities to monitor each
phase in a manufacturing process to ensure consistent quality and output. With on-line
or portable readers, scanning of a routing sheet with bar codes on them as parts or sub-
assemblies are completed, enables work-in-process costs and manufacturing progress to
be tracked.
• Labor or Assembly Tracking
Similar to work-in-process, bar codes for labor tracking of a manufacturing process
ensure the consistent quality and output of a job. Consider the following example: In a
custom assembly, a terminal leads the operator in what to assemble. As the operator
scans each part or sub-assembly added, the computer can monitor it for correct
specifications. Should a manufactured part be found faulty, it can then be tracked back
to the exact point and/or person responsible for the error.
• Time and Attendance
Time and attendance is yet another popular application for bar codes. An employee
badge with a bar code can be read into a computer terminal at clock-in and clock-out
stations to provide attendance data to a computerized payroll program.
• Asset-Tracking
Bar codes can help companies to track their assets by way of equipment or hardware
that they may temporarily loan out to someone. A bar code placed on a rental video,
for example, is scanned at checkout along with the borrower’s ID card enabling the
item to be tracked while it is on loan.
• Warehouse Picking
Involves a computer that downloads a list of items to a portable data terminal that
instructs a warehouse worker to pick those items associated with a specific order. As
locations are reached or items are picked, the bar codes are scanned and the terminal
compares what was scanned to ensure that the right location or item is being picked.
After picking the order, the worker goes back to the terminal to upload the data to the
computer mainframe and to receive his next order of instructions for picking.
The afore-mentioned applications are examples of popular manufacturing related uses for bar
coding. It is important to remember, however, that text and bar code labels have a multitude of
traditional and/or specialized usage capabilities outside of the manufacturing realm as well.
When faced with a labeling or bar coding problem, it is often human nature to gravitate toward
a familiar technology or approach in the solution. Dot matrix printer users, for example, may
initially consider using a dot matrix printer for the task. Those most familiar with ink jet or laser
printers may first design a laser or ink jet printer into their bar code system. This approach can be
a valid first step as it provides a benchmark for comparison of performance and cost.
However, to ensure maximum efficiency, reliability and good design sense, a second design stage
is required. That is, to carefully assess the labeling application and to explore the available bar
code printing technologies that offer the best performance and cost effectiveness for that
application. In order to be successful with this approach, the user and/or specifier must
thoroughly understand the labeling application and the benefits and limitations of each of the
alternative, available print technologies.
In assessing the labeling application, numerous details must be taken into consideration,
including:
When labeling unique items, where the label has to be matched to the object it is to identify, a
print bureau may not be practical, particularly for large quantities of labels without an
Part # 11878L Page 8
Barcoding & You
obvious sequence. Here, the difficulties of applying the label to the correct object may
preclude the use of a print bureau and make a good case for the use of a demand printer.
Demand label printing is also a must when labels containing large amounts of variable data or
when the information is only available, at or just before, the time the label is to be applied.
Based on your answers to these questions, you are now ready to choose a print technology and
resultant printer from those available on the market with the desired options and suitable print
speeds to meet your specific application needs.
Some of the most popular choices for bar code printing are dot matrix, ink jet, laser and thermal
printing. These print technologies each relate to Component 1 of the barcoding requirements
mentioned earlier on Page 4. To understand how each technology varies in execution and
strength, let us take a moment to review each print method in detail assessing their respective
strengths and weaknesses.
1. DOT MATRIX
Dot matrix print technology is one of the oldest techniques used for on-site label printing.
The typical dot matrix bar code printer is a modified line printer requiring pin feed paper
stock. Solenoid driven needles impact an ink coated nylon ribbon, transferring ink onto
the paper or label. The image is built up dot-by-dot in a matrix as the needle and paper
are moved relative to one another.
J ADVANTAGES
Dot matrix printers are readily accessible and inexpensive to purchase.
They can print on virtually any type of form, check or document and can print on
wide-web, multi-part (carbon) forms.
Dot matrix printers use multi-pass ribbons which can result in reduced overall cost for
ribbons and the label material.
L LIMITATIONS
Dot matrix printers print low to medium density bar codes that may not meet certain
end-user guidelines. The dot size on the matrix printer limits the narrow element size
and density of the barcode. The following example, compares sufficient dot overlap
versus unacceptable dot overlap on a dot matrix printer used to print bar codes.
2. INK JET
Ink jet printing is a common direct marking process and a favorite on high speed
production lines. Ink droplets are selectively deflected between a moving product and an
ink return channel. Ink jet printing is frequently used for coding products and cartons with
human readable data and lot codes at very high speed and for case coding of cartons with
bar codes.
J ADVANTAGES
Common direct marking process on a product or carton that involves only one step
compared to label printing which requires two steps: printing a bar code label and
adhering it to the product.
A favorite on high speed production lines due to its “mark-on-the-fly” capability.
“Mark-on-the-fly” being an affectionate term to describe this print process within the
industry.
Used primarily for industrial use amongst large conglomerate organizations due to the
affordability issue and high product volumes.
L LIMITATIONS
Costly system installation designed for high volume of product labeling – not for
individual or small batch label bar code printing.
Routine maintenance and supervision required to ensure consistent print quality and to
prevent ink jet “clogging”.
Limited dot placement accuracy and bar code density due to ink splatters and product
being in continual motion.
Material to print on is restricted due to the advent of ink bleed on some materials.
Poor contrast of bar codes on corrugated box materials due to their dark backgrounds.
Properly matched scanning devices must be chosen to ensure bar code reliability.
3. LASER
The laser printer works much like a photocopier projecting controlled streams of ions onto
the surface of a print drum resulting in a charged image. The charged image then
selectively attracts toner particles, transferring the image onto the paper substrate by
means of pressure. The pressure from the printhead and drum then fuse the image to the
paper, creating the image.
J ADVANTAGES
Laser printers are good at producing bar code labeled documents on plain paper.
They can print high quality text and graphics on paper documents and can double as a
document printer when not being used to print bar codes.
Bar code density is also quite high on laser printers resulting in a scannable code at
virtually any wavelength using an infrared scanner.
L LIMITATIONS
Laser printers are not well suited for industrial labeling applications or individual
product labeling applications. Here, they prove inadequate and wasteful as it is
impossible to produce single or small labels. (A minimum of a ½ a page of media is
typically required for the printer to maintain control of the sheet. Unless the label is at
least that size or multiple labels are needed at once, the remainder is wasted).
Laser printer labeling adhesives must be carefully selected to ensure stability under the
heat and pressure of the fuser. Otherwise, it may extrude onto the printer mechanism,
where it will capture stray toner or “curl” at the edges. Because of the pressures used
in the laser printer image transfer process, many laminated label materials are not be
compatible with this technique. Those materials that are compatible may not always
be available in sheet form for the laser printer to be able to print on.
A laser printed label is only as durable as a photocopy of paper. They commonly
cannot produce chemical or water-resistant labels with the image longevity of a
thermal printer.
Cost of laser toner cartridges for bar code printing is significant and can be costly. A
5% black density, for example, is commonly required for standard word processing
versus a 15-30% black density for bar code printing. Bar code printing on a laser,
therefore, is 6 x’s more expensive than standard word processing printing!
1. DIRECT THERMAL
Direct thermal printing is an old technology originally designed for low cost copiers and
fax machines that utilizes chemically coated paper. It has since been transformed into a
highly successful technology for bar coding. The thermal printhead is typically a long
linear array of tiny resistive heating elements (about 100 to 300 per inch) that are arranged
perpendicular to the paper flow. Each thermal printhead element locally heats an area on
the chemically coated paper directly under the print element. This induces a chemical
reaction which causes a black dot to form in that area. The image, itself, is formed by
building it from dot rows as the media passes underneath the active edge of the printhead.
J ADVANTAGES
Direct thermal printing is an excellent choice for many bar code applications because
of the consistent, sharp edge image print quality that they can generate.
Direct thermal is ideal for applications with a short shelf life requirement – meaning
the label is not required to last very long. Many packaging companies utilize direct
thermal technology since the address and package tracking labels only need to last
long enough to reach their destination which is typically accomplished in a few days.
Direct thermal printers provide simplicity and environmental economy with re-
cyclable materials available.
Direct thermal printers are simple to operate compared to most other print
technologies – no ribbon or toners to replenish or monitor.
Low, long-term maintenance cost compared to comparable technologies
Enables batch or single label print capability with virtually no waste.
Direct thermal is durable compared to other comparable print technologies.
Office and/or limited industrial application usage, though more limited in application
than thermal transfer due to its shorter image longevity.
L LIMITATIONS
Direct thermal printing is extremely sensitive to environmental conditions – e.g. heat
and light (fluorescent and/or direct sunlight).
Direct thermal paper remains chemically active after printing. Because of this, all
thermal paper materials used – labels, tags or ticket stock – are top coated to resist UV
light exposure, chemicals and minimal abrasion.
2. THERMAL TRANSFER
Thermal transfer printers use the same basic technology as direct thermal printers, but with
the elimination of chemically-coated media material in favor of a non-sensitized face stock
and a special inked ribbon. A durable, polyester ribbon film coated with a dry thermal
transfer ink is placed between the thermal printhead and label. The thermal printhead is
used to transcribe the ink onto the label surface, where it cools and anchors to the media
surface. The polyester ribbon is then peeled away, leaving behind a stable, passive image.
ADVANTAGES
High contrast, crisp image bar code print quality with a durable, long-life and archival
image stability.
Ideal for batch or individual label print capability – with virtually no waste.
Low, long-term maintenance cost compared to comparable technologies
Maximum readability and IR scannability
High contrast text, graphic and bar code print capability
Durable for operation in office or industrial applications
Capable of printing on an unlimited variety of media stock – except multi-form
L LIMITATIONS
Cannot print on media without use of ribbon – resulting in higher supply costs over
direct thermal which, by comparison, only requires media to operate and no ribbon.
Single pass thermal transfer ribbon can be wasteful if little is printed on it.
Ink transfer ribbon is a poor candidate for re-cycling
To obtain optimum print quality in thermal transfer, the ribbon and media substrate
MUST be compatible. Otherwise, the heat from the printhead could melt the ribbon
onto the label causing internal printer problems.
For most engineers involved in bar code system automation deciding where a bar code printer is
appropriate is a straightforward task. But specifically, when should a thermal printer be
considered?
Direct thermal or thermal transfer printers can be specified for use in applications when any of the
following criteria are specified:
• A point-of-application system is required
Point-of-application refers to the requirement for a label to be generated at the exact time and
location where it is to be applied to the product in question. In a manufacturing process,
point-of-application labels are frequently required to label the product for product
identification purposes or to label the product packaging in preparation for shipment.
• Individual and/or batch printing of labels with variable data is frequently produced
Thermal printers are ideal for applications that require individual or batch labels that contain
variable data bits or fields that change frequently and cannot be serviced by an outside
printing agency. In such cases, thermal printers promote efficient and flexible label
production with virtually no label waste, enabling users to print only what they need when
they need it.
• Alternating label widths and/or length materials are frequently being used
Thermal printers are ideal for labeling applications with varying label widths and/or lengths
because they adapt to varying size labels easily and promote label production without waste.
Comparable available print technologies, such as laser or dot matrix, cannot make such
claims because of the waste factor and the limited availability of label materials and/or sizes
in sheet or pin feed format.
• Graphics printing and/or unlimited adjustable (scalable) text font sizes are desired
Thermal printers not only promote user-flexibility to print individual or batch labels on
alternating size media. It is the only print technology whose software permits you to
incorporate and print virtually any custom graphic or international symbol, be it your
corporate logo or other related universal graphic icons such as Fragile, UL, or Flammable
into the label design. Text fonts are also scalable meaning that they can be adjusted to any
point size requirement. Bitmap fonts, by comparison, are only adjustable to a limited
number of point sizes – e.g. 8, 10, 12, 14, 16 or 18 point sizes. A printer’s a capacity to
operate such text fonts or to download graphic formats is dependent on the amount of
memory that the printer has to adequately store and process such information. The more
memory a printer has, the more complex fonts operations it can perform and process more
quickly and efficiently.
• High density bar codes are needed
Thermal printing is ideal where high density (crisp, high definition/contrast) bar codes are
required. Thermal print bar codes also have one of the highest scanner read rates compared
to comparable print technologies.
• Clean, quiet, compact printer operation with low maintenance and operating cost is
preferred
Thermal printers are highly compact promoting clean, quiet operation compared to
comparable print technologies, such as dot matrix or ink jet printing, for example. Thermal
printers come in two basic varieties – tabletop and desktop. Tabletop thermal printers are
typically bigger than desktop thermal printers in size primarily because of their ability to hold
a full 8″ roll of media compared to the 3-5″roll capacity of a standard desktop printer.
(Larger roll capacity enables users to print longer without frequent interruptions to change or
replace media which can effect one’s overall productivity, dependent on the number of
printed labels required).
From a space consumption perspective, tabletop printers typically take-up the surface area of a
typical office laser printer, whereas a desktop printer utilizes about the surface area of a typical
office phone or standard mouse pad. This surface area or space consumption comparison is
typically referred to as the printer’s footprint within the bar code industry.
From a cost perspective, thermal printers tend to have a higher initial cost but a lower long-term
maintenance and operating cost compared to standard office or document print technologies.
This is due, in part, because thermal printers are considered a specialized print technology,
accessible through a limited number of channels compared to that of popular office printing
equipment which is readily available at any retail store. In the long-term, the total cost of
ownership of a thermal printer is lower due to (1) lower maintenance costs; (2) efficient label
production with the decreased occurrence of label waste; and (3) steadily decreasing prices of
ribbon and thermal based papers. Lower long-term maintenance costs quickly offset one’s initial
investment cost enabling a rapid return on investment to be realized, especially when coupled
with the increased efficiencies of bar coding automation on the whole.
The selection of the most suitable thermal printer is dependent on a number of variables that
collectively dictate a printer’s overall sticker price. In general terms, the more printer features
and options one chooses– the higher the printer’s sticker price.
Having completed the exercise of outlining one’s application requirements and budget criteria,
you can now proceed to analyze which thermal printer model is best suited for your application
based on the following printer performance variables:
In terms of label longevity and stability, thermal transfer is the only alternative if crisp, long-
lasting images are required to last for a number of years - e.g 1 or more years. Direct thermal
printers, in comparison, are ideal for short-term applications where the label is only required
to last for a limited amount of time – e.g. 1 week to 1 year. Bear in mind that direct thermal
is not as durable as thermal transfer, especially when exposed to direct sunlight or other harsh
chemicals. Direct thermal paper varieties are also somewhat more limited than those
available for thermal transfer printers.
• DPI RESOLUTION
All Zebra printer models offer a standard of 203dpi resolution. Certain Zebra models,
however, also offer higher print resolution options like that of 300, 400 or even 600dpi.
Depending on your application, higher resolutions or dots per inch may be required to
facilitate the printing of text and bar codes on small or miniaturized labels, such as those
commonly used in the electronics or pharmaceutical industries for component or specimen
labeling. Higher print resolutions enable more detailed labeling (often highly miniaturized
and compact) to be accomplished without impairing print quality and scanner readability.
• PRINT SPEED
Print speed is yet another factor that differentiates one Zebra printer from another. Some
printer models can outperform others, printing at a maximum print speed of up to 12ips
(inches per second). Others can print only at a maximum print speed of 2ips, while still
others can operate only within designated ranges between 2 and 6ips, for example.
Depending on your application and the daily volume of labels that is required, print speed is
an important issue to consider to ensure that your specified daily volume requirement is met
and that the printer can produce labels as quickly as they are required.
• PRINT WIDTH
Print width, similar to print speed, differs from one Zebra printer to another. Many of
Zebra’s printer models are designed to print 4″ wide labels. Still others print can print 3″,
5″or 6″ labels. The widest available print width on a Zebra printer is 8.5″. Depending on the
application and your required label width (e.g. the widest label you will need to print), print
width becomes yet another criteria that one must consider in choosing the right printer for the
job. Note: Label images can frequently be rotated to print in landscape or portrait mode
through the printer programming code or software, which in the case of Zebra is ZPLII® and
BAR-ONE®.
• PRINTER OPTIONS
One of the last factors to consider when purchasing a thermal printer are the printer options
that are required and/or desired for the application or user operating the printer. Depending
on the printer manufacturer some such options may be offered as built in standards while
others may be available only for a cost.
Zebra printers, in particular, are available with a number of options to choose from,
dependent on the requirements of the application and the user’s preferred mode of operation.
Depending on the printer model, these options can include:
(1) Diverse Print Modes (e.g. cutter, peel, tear, internal rewind, auto-calibration);
(2) Flexible Communication Options (e.g. parallel, serial, twinax, coax, ethernet); and
(3) Numerous Flexible Memory Options (e.g. - flash, PCMCIA, increased DRAM) and/or
font options (scalable versus bitmap, Non-roman (or international character symbols)
versus TrueType®).
Many Zebra printers offer such options as standard features which naturally has a bearing on
printer list price. As a general rule of thumb, the fancier the options – the higher the printer list
price. Any of these options, incorporated either independently or in conjunction with one
another into a printer can help it to perform and adapt more readily, not only, to the constraints of
your application, but more importantly, to the user’s preferred mode of operation and/or work
habits. The peel mode option, for example, when installed on a Zebra printer can facilitate
quicker label application for a user. In peel mode, the printer will actually separate the label from
its liner backing making it easier for the user to grab and simply adhere the label to the item
versus having to remove the label from its liner manually. Such time saving options can greatly
facilitate label output and in some cases even improve worker morale.
More importantly, however, when a proper balance is reached between printer performance
capability and application criteria and/or budget, the printer becomes a more natural extension of
the worker or operator, facilitating their ability to do their job more efficiently. Thus, increasing
their overall productivity which translates to increased profits and money savings to the
organization as a whole.
Zebra designs and manufactures complete labeling solutions that integrate application and print
systems expertise with software and specialty supplies. Zebra offers the broadest line of bar code
printers available on the market today.
Zebra’s recent merger with Eltron serves to round out our product assortment so as to capitalize
on the unique brand strengths of both companies. Zebra brand’s dominance in the manufacture of
reliable, high performance tabletop printers coupled with Eltron brand’s superiority in the desktop
and card printer arena, ensure that our customer’s specific application requirements are met.
The comprehensive Zebra/Eltron product line includes fully compatible, industrial thermal
transfer, direct thermal and card printers. The units range from low-cost, general purpose printers
to highly specialized models tailored for custom applications and system requirements.
• Eltron’s Strata® is a cleverly contoured, low profile, all metal wide-web printer ideal for
industrial applications which have space and budget constraints.
• Eltron’s Eclipse® printer delivers a low cost, full-sized printer solution that is ideal for
applications with basic requirements.
• Eltron’s LP/TLP2700® Series are reliable, on-demand printers ideal for dedicated
applications which are budget sensitive and have high quality label requirements.
• Eltron’s stylish Orion provides an extremely easy-to-use desktop printer utilizing
OpenACCESS™ technology for applications requiring a simplistic solution to generate
low volume, high performing/quality labels.
• Eltron’s Companion Plus® printer is the perfect mate to retail operations with a sleek,
compact, durable receipt printer at the industry’s lowest price.
• Eltron’s Aura® printer offers an affordable printing solution in a small, simple to use
device for novice users working in home offices or small business environments.
Zebra’s line of specialty ribbons and media supplies, from tear-proof Tyvek® to UL Recognized
polyester and scratch resistant Z-Ultimate® facestocks completes the product range. Zebra
supplies, when combined with the superb printing capabilities of the Zebra printers, produce
consistently durable labels, tags and tickets for all your marking and tracking needs. And if you
have a labeling application that cannot be solved using existing Zebra supplies products, Zebra’s
research specialists can design a customized labeling solution for you, utilizing special die-cuts,
adhesives and facestocks. Zebra’s label presses also have the capability to preprint labels, tags or
ticket media stocks in up to four different colors, in perforated or fanfold variety.
For more detailed information , specification sheets are available for download on our website
(www.zebra.com) which highlight the specific features, options and performance capabilities of
the entire Zebra Printer Product Line encompassing our printers, software and supplies.
Regardless of your application or budget criteria, Zebra/Eltron printer products, software and
supplies are guaranteed to deliver quality performance at a price point suitable to your needs.
Zebra Z-Series
Zebra Performance Line
Zebra S-Series
BAR-ONE® Label Creation Software
Zebra® Supplies
The key to specifying the correct media, similar to the correct printer, involves a solid
understanding of the application. Zebra recommends analyzing the following label supplies
related issues in conjunction with your thermal printer selection:
• MEDIA TYPE
Thermal printers are designed to operate with a variety of media types, including pressure
sensitive, die-cut, butt cut, perforated, notched, hole-punched, continuous, tag or ticket stock
labels. The diagrams below highlight some of the most popular label varieties used:
Dependent on the type of media sensors the printer has will often dictate its ability to operate
with certain media type varieties. Zebra printers come equipped with a variety of media
sensors that enable the printer to gauge vertical label length during the media calibration
process.
Calibration is a process that a printer performs in order to gauge the length of the label
material loaded within it. Sensors within the printer’s media compartment – commonly
located around the printhead - detect either the white spaces (inter-label gaps) or black marks
and/or notches on the reverse side of the label stock that represent a label’s actual face size
(length). Printer calibration ensures that one’s data is aligned and prints correctly on the label
stock.
Zebra printers can be configured to contain any one of the below sensor varieties:
• Transmissive Media Sensor – is used to gauge label length for media with visible
interlabel gaps, notches or pre-punched holes. Light from the sensor passes through
the gaps in the label materials semi-transparent backing enabling the printer to
measure label length during calibration.
• Reflective Media Sensor –similarly, a reflective sensor emits light which is reflected
back to the sensor when it reaches a black mark appearing on the reverse side of the
label stock. Such specialized media is commonly referred to as black mark media.
• Dual Media Sensor – two sensor within the printer (one reflective and one
transmissive) that have the ability to detect both interlabel gap and black mark media,
irrespectively. Zebra Performance Line printers come equipped with dual processors
that have the capability of sensing all kinds of media.
• Multi-functional Sensor – refers to a single sensor within the printer that has the
ability to detect both interlabel gap and black mark media, irrespectively. Zebra Z-
Series printers come equipped with multi-functional senors that have the capability of
sensing all kinds of media.
• APPLICATION SURFACE
Application surface is another important factor to consider when selecting the right media to
operate within the constraints of your application. Application surface refers to the type of
surface upon which the label will be applied. Surface features can be flat, smooth, curved,
rough, rigid, flexible, clean or contaminated (dust, oil, powder, etc). Certain media types
may be better suited to deal with certain application surface criteria than others.
• ADHESIVE TYPE
Adhesive type refers to the label’s level or degree of adhesiveness. Generally speaking, there
are two types of adhesives, acrylic and rubberized. A rubberized adhesive label is a pressure-
sensitive adhesive based on natural or synthetic rubber. Rubber based adhesives offer good
general purpose performance and may be used on a wide variety of surfaces and temperature
ranges. They can be used on most packaging materials, including plastic, glass and metal.
Rubber based adhesives provide excellent adhesion to corrugated materials. Most
importantly, rubber based adhesives have a high initial tack. Meaning they stick
immediately to a surface which makes them particularly useful on curved or irregularly
shaped surfaces.
durability. Acrylics are extremely strong and resistant to environmental conditions which
make them suitable for heavy duty applications.
In addition, some label media varieties come equipped with a permanent adhesive while
others are removable enabling them to be lifted off and re-adhered again elsewhere. Still
others are recyclable, freezer-grade, patterned or tamper evident:
• Tamper evident labels have acrylic adhesive whereby a pigmented adhesive is used
to leave the word “VOID” behind on the product if the label is removed. Such labels
are ideal for labeling physical assets where security is essential.
• APPLICATION TEMPERATURE
Application temperature refers to the minimum or maximum temperature present at the time
the label is to be applied to the item or product in question. Application temperature is
important in that some adhesive materials are better suited to deal with extremes in heat
and/or cold. A label that is not suitable to the application temperature it is subjected to may
not stick properly. Thus, defeating the whole purpose of bar coding as a means of automating
certain functions or processes.
• SERVICE TEMPERATURE
Service temperature differs from application temperature in that it specifically refers to the
temperature range that the label must withstand throughout its useful life. Zebra’s Supplies
Selector Guide is a helpful reference tool that can be used in order to gauge the application
and service temperatures for our various media types.
• EXPOSURE
Exposure refers to the type of environmental conditions and/or stresses that the label or tag
must withstand. Common stresses found in labeling applications to take into consideration
when choosing a media type include moisture/humidity, chemicals, abrasion, sunlight, heat,
cold, blood etc. Any such factor when coupled with the wrong media type that is not
designed to withstand such stress can result in poor print quality, printer jams or fading.
information runs the risk of being misread by a worker which can sometimes cause errors.
Infrared scanners, though a reliable form of data capture and transmission, operate best when
used within certain distance ranges. When purchasing a scanning product, it is important to
make sure that the scanner can perform within the distance range you need it to. Scanner
manufacturer’s do specify the distance read capability of their product on their specification
sheets.
• METHOD OF APPLICATION
Method of application refers to the manner in which the label is to be applied. Label
application can be accomplished, primarily, in one of two ways – e.g. by hand or by utilizing
a label applicator system. Hand application is the more economical approach, yet it is not as
expedient compared to that of an applicator system. Applicator systems are frequently
accomplished utilizing pneumatic cylinders. A conveyor or pneumatic cylinder system can
align and position a product toward a labeling station where a pneumatically driven applicator
arm then adheres a peeled label to the side of the product. Such applicator systems can be
either simple or complex in nature which naturally require a larger budget to accomplish.
• RE-CYCLABILITY FACTOR
For some applications, recyclable label material may be preferred. Linerless label stock is a
perfect example of how an ecological concern for the environment resulted in the production
of more environmentally friendly label materials. Linerless label media, as its name suggests,
utilizes no liner backing. It commonly consists of continuous media with no perforations. Its
top surface can be printed on, whereby its reverse side contains a light adhesive. Thus,
foregoing the need for the liner altogether. Linerless label materials are particularly popular
in many European countries. In light of this trend, Zebra/Eltron offers a number of printer
models that have this specific print capability.
• BUDGET
Whether choosing a printer or labeling supplies, one’s budget for spending plays a critical
part in the product selection process. It is essential not to overlook the cost of labeling
supplies in reviewing one’s application. In all actuality, the label itself should always be
your first area of concern. From its size, content, industry compliance and material type, to
the selection of the appropriate printer to print that label with - one’s entire labeling
application revolves around the label. One’s budget concessions, therefore, must effectively
take both areas of label supplies and printer selection into account.
As for the future of bar coding and whether it has achieved its full potential?
Not the way we see it! The possibilities of bar coding are practically endless. With a
commitment to research and development, Zebra will leave no stone unturned in our quest to find
better ways to make bar coding work for you and to build better products to meet your specialized
needs. We will never be satisfied with status quo so as to continue to provide our customers with
the highest quality bar code products and services available.
Your local Zebra reseller is trained to help you find the right barcode labeling solution to improve
your current processes, cut costs, and eliminate human errors. From our broad line of printers,
supplies, and software, Zebra and Zebra sales partners can provide you with a labeling solution
that is custom-tailored to your specific needs.
In addition, Zebra offers a variety of specifying tools and bar code reference materials to assist
you in your planning. By accessing our website at www.zebra.com, users can view and obtain a
vast number of tools and general bar code information for immediate download and print.
Finding a domestic or international reseller partner near you via our website is also a breeze.
Simply enter the region of the country (e.g. - US or International), the product category of
interest (e.g. –Zebra bar code printers, software, or labeling supplies) and your zip code, and our
website will recommend the reseller partner(s) closest to you to call on for further assistance.
With our 20+ years of experience in the bar code industry and our world-wide network of value-
added sales partners, we hope that you will consider Zebra as a possible solution provider and
trusted resource in helping you find the right thermal printer solution to fit your needs. Trust a
recognized source with your bar coding needs and you too can position yourself comfortably
ahead of the competition!
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