Thermal Transfer Ribbons

Thermal transfer ribbons are specifically designed for use in thermal printers. The ribbons consist of a thin film coated on one side with a layer of ink usually made from wax or resin. When heated by a thermal printer the ink melts and transfers onto a substrate (such as a tag or label) and creates a high-quality and durable print. This method of printing is favoured for its precision and ability to produce long-lasting images and is used for a variety of industrial and commercial purposes across the UK.

The printer’s thermal print head applies heat to the ribbon, which then melts the ink onto the label material. This happens as the ribbon passes over the print head and thousands of tiny elements heat up in patterns to melt the ink at the locations needed to form any text or images. The melted ink cools and then solidifies on the label material which leads to a very durable and very high quality print. This method of printing can be used on papers and synthetics which makes it useful for numerous applications.

Thermal transfer ribbons are categorised into three types based on their ink compositions: wax, resin, and wax/resin blends. Wax ribbons are the most economical, and ideal for printing on paper labels. Resin ribbons are suited for outdoor environments and have higher durability. Wax/resin blends offer a balance between durability but can also be printed on a variety of different materials.

Wax ribbons are used on paper materials and are often used for more general labelling, they give excellent print quality for normal handling conditions. Resin ribbons are designed for more demanding environments and provide durability and resistance to chemicals, temperature extremes, and abrasion and are often used on synthetic materials. Wax/resin blend ribbons are in the middle having some of the durability and resistance of resin and the usability of wax.

There are environmentally friendly options for thermal transfer ribbons especially with industry shifts towards sustainability. The eco-friendly alternatives are usually made from biodegradable materials and the printers themselves can be designed to use lower temperatures and less energy. Some manufacturers are taking steps to reduce plastic content in the ribbon’s cores and packaging or offering recycling programs for these plastics.

How long a thermal transfer ribbon lasts depends on a few factors, including the type of ribbon, the frequency of printing, and how long a print run lasts. Wax ribbons usually have the shortest life span, and resin ribbons last longer due to tougher inks. The standard ribbon can usually print a thousand labels before needing to be replaced – but the most common thing to look for is a decline in quality (which indicates the end of a ribbon lifecycle).

Thermal transfer ribbons made from resin-based inks are particularly suited for outdoor labels. Resin ribbons create prints that are resistant to environmental conditions like UV lights, extreme temperatures, moisture, and chemicals. This all makes them ideal for use in the outdoors and keeps the print in good condition for a long time.

Thermal transfer ribbons should be stored in a cool, dry, place and away from direct sunlight. The best storage conditions include maintaining a consistent temperature and humidity level at 5-35°C (41-95°F) and 45-85% relative humidity. Ribbons should be kept in the packaging until ready for use and to protect them from dust and other contaminants. Following these steps prevents the ribbons from drying out or sticking together, which can hurt print quality.

First, make sure that the ribbon is correctly installed and compatible with the printer and the label material. Check the print head is clean, or if there is any sign of damage and wear and tear. Once you’ve done this, try adjusting the printer settings, such as print speed and temperature, to match the ribbon and material specifications. If you still have issues, try again with another ribbon or consult with the manufacturer to help troubleshoot the problem.

Thermal transfer ribbons are versatile and capable of printing on a wide range of label materials. However, the choice of ribbon type should match the label material for optimal print quality and durability. Wax ribbons are best suited for paper labels, and ideal for general use and standard applications. Wax/resin ribbons work well on both paper and some synthetic labels, offering greater durability. Resin ribbons are recommended for use with synthetic materials, such as polyester and polypropylene.

Wax/resin blended ribbons offer better durability in comparison to pure wax ribbons. This makes them suitable for applications where the labels might have to handle some handling, abrasion, or limited exposure to chemicals. Pure resin ribbons provide the highest durability labels that thermal transfer ribbons can provide as they are built to withstand extreme temperatures, exposure to chemicals, and prolonged outdoor use.

Thermal transfer ribbons can be custom-sized to meet specific requirements. Labelservice offers customers the flexibility to print with ribbons of various widths and lengths – manufacturers produce ribbons in all kinds of sizes to fit a wide range of thermal printers. Customising the size allows businesses to better optimise their label printing, reduce waste, and potentially lower costs.

A wide variety of industries make use of thermal transfer ribbons thanks to the versatility and durability of the prints they produce. Some of the bigger sectors include retail – for things like price tags and shelf labelling. The healthcare system uses these for patient identification and specimen labelling. Manufacturing industries use these for product identification, tracking, and regulatory labels. Logistics and shipping uses these for shipping labels, tracking barcodes, and inventory management. Thermal transfer shipping labels are used in any environment where labels need to last a long time and remain legible.

Thermal transfer printing generally has higher upfront costs due to the ribbons and specialised printer hardware, but can often work out to be significantly cheaper in the long run. This is especially so if more durable and longer-lasting labels are needed. Generally speaking, thermally transferred print labels last a long time and don’t need to be replaced as often – which reduces waste and lowers overall label costs. It’s particularly cost-effective for industries where the integrity of the label information is important over longer periods. 

Thermal transfer ribbons are generally sage, but there are some precautions to ensure safety. It is advised that you avoid direct contact with the ink side of the ribbons as these can potentially irritate the skin. You should always wash your hands after handling the ribbons and avoid touching your face or any food until you have done so. It’s also a good idea to install ribbons in a well-ventilated area to avoid inhaling any particles. If the manufacturer recommends any PPE (personal protective equipment) you should follow their guidelines.

Thermal transfer ribbons are usually available in black – which is good for most labelling requirements. Coloured thermal transfer ribbons are also available in a variety of hues (red, green, blue, yellow, etc.) Coloured ribbons can be useful for some industries that use colour coding or for any aesthetic design purposes.

There are some good rules of thumb to follow to reduce ribbon waste and increase efficiency, such as – adjusting the printer settings to match the specific ribbon and label material being used. Some thermal transfer ribbons come with an economy mode, this reduces the ribbon usage on parts of a label with no print. Use the correct size ribbon for a given label to minimise waste. It’s also always recommended to regularly maintain the printer to prevent any issues that could lead to ribbon wastage – like misalignments or unnecessary reprints.

Disposing of thermal transfer ribbons responsibly is important to negate any environmental impact. A large proportion of ribbons are made from materials that aren’t biodegradable – but suppliers may offer recycling programs for used ribbons and cores. Failing that, dispose of ribbons according to local regulations (there may be a specific bin or place to process this kind of waste).

Thermal transfer ribbons are compatible with both flat-hard and near-edge thermal transfer printers. The only difference is the ribbon formulation and print head technology of the two types of printers. Near-edge printers tend to operate at higher speeds and need ribbon inks that melt at a lower temperature but Flat-head printers work with a broader range of ribbon types. Generally, manufacturers will have specifications on what printers the ribbons are compatible with.

The print speed capability of thermal transfer ribbons will vary depending on the ribbon speed formulation, the model of the printer, and what material is being printed on. Thermal transfer printing can accommodate a reasonably wide range of print speeds – some systems can print at up to 12 inches per second (ips) and more. For more high-quality prints and tougher materials, it may be necessary to use slower print speeds.