5 ways thermal printing labels save you time and resources

Getting the right label for a pharma lab or semiconductor manufacturing plant isn’t as simple as those packaged inkjet labels you can buy at any stationary store. In high-tech industries, labels need to not only convey precise information, but they need to meet a variety of other durability, sterility, and clean requirements.

To do this successfully, it might appear that your labels need to be fully preprinted during production. And sometimes that is the case — but not always. There are a lot of use cases where information needs to be added to a label in the moment. Quality control labels, QR code labels for tracking, and sterility indicators, for example, are helpful because they convey up-to-date  information like date, time, batch number, inspector initials, and other information that just can’t be preprinted. 

Thermal printing labels give you the best of both worlds. They can be preprinted with evergreen information and then easily re-printed on site to add process-specific information. And, they’re durable enough for even the harshest environments. 

What are thermal printing labels?

When we talk about thermal printing, we’re really talking about two types of printing — direct thermal printing and thermal transfer printing. Both offer high precision and durability, making them  ideal for industries with strict durability and legibility requirements, but each has its own unique advantages and disadvantages as well.

In direct thermal printing, the label material itself is heat-sensitive, meaning no ink or ribbon is required. When the printer applies heat, the label darkens in specific areas to form the desired text or image. This method is simple, cost-effective, has high chemical resistance and can handle smaller text sizes, but the labels are more prone to fading over time, especially when exposed to heat, light, or friction.

Thermal transfer printing, on the other hand, uses a heated ribbon to transfer ink onto the label, resulting in a more durable and long-lasting print. This method can be used on a wider variety of materials, including synthetic labels (like polyimide labels and their alternatives), which are resistant to heat, chemicals, and abrasion. Thermal transfer printable labels are commonly used in environments where labels need to endure harsh conditions, such as in semiconductor manufacturing, pharmaceuticals, or automotive industries, making it a versatile choice for high-tech applications.

Fully preprinted labels don’t fit every scenario

There’s a place for fully preprinted labels: primarily in situations where large-volume consistency is a priority. Product or packaging labels that are the same for each unit and need to be uniform across large quantities, for example, are an obvious choice for full preprinting. It’s lower cost and more consistent. 

But there are the limitations we mentioned at the beginning of this article. Fully preprinted labels just can’t accommodate information that changes frequently or unexpectedly, like inspections, serial numbers, and tracking codes. Additionally, preprinted labels can become a financial burden if your processes or product change. Rather than updating labels on the fly, you waste any labels already in stock and have to wait for new labels to be produced and shipped.

Blank thermal printing labels also have pros and cons

The other extreme is a blank thermal printable label that you fully print on site. This too, has some advantages.

• Full customization on demand — Whether it’s a regulatory update that changes labeling requirements or product variations that call for new information on labels, real-time customization is crucial. Onsite thermal printing enables businesses to quickly and easily adapt their labels to meet these changes. 
• Minimized waste — Fully onsite printing allows you to print only what is needed, when it is needed. So no label stock is wasted if you change directions.

These advantages are valuable, but full on-site printing has its downsides too. 

• Decreased efficiency — On-site printing is slower than factory preprinting of information that’s the same across all labels. What might seem like an insignificant amount of additional time spent printing an individual label adds up to serious slowdowns over thousands or hundreds of thousands of labels.
• Inconsistency — Labels printed on-site are inherently less uniform than factory printed labels because of environmental and user differences from print batch to print batch. 

Partially blank thermal printing labels are the sweet spot

Using thermal printing labels that are partially preprinted during production with blank spaces left for on-site printing of more transient information is the best of all worlds. Here are five key ways they save you time and resources:

1. Save time

Partially preprinted thermal labels save valuable time by allowing companies to print static elements, such as company logos, branding, or regulatory information, in advance, which is faster per label than on-site printing.

2. Track variable data

One of the key advantages of partially blank thermal printing labels is the ability to customize variable data onsite. Information such as batch numbers, dates, and barcodes can be adjusted in real-time, allowing companies to track products and maintain accurate records throughout the production process. 

3. Increase consistency

By preprinting static elements like logos and branding, companies can ensure that the brand and compliance-related information on their labels remains consistent across all product lines. 

4. Reduce errors

Partially printed thermal labels significantly reduce the risk of errors in the labeling process. When static information — such as regulatory symbols or company details — is preprinted, there’s less room for mistakes, especially in fast-paced or complex production environments where mislabeling can lead to costly recalls or compliance issues. 

5. Eliminate label failure

By using partially preprinted thermal labels that are specifically designed for durability and resistance, companies can ensure that essential information remains intact and legible even in harsh environments. 

The role of thermal printing labels in your industry

Not every industry needs the durability and flexibility of thermal printing labels that can be customized on site, but it’s essential in high-tech fields where environmental and process requirements are complex and precise. 

Semiconductor manufacturing

The components used in semiconductors are intricate, and many are exposed to high temperatures during the manufacturing process. Labels must withstand these harsh conditions without compromising clarity or durability. Thermal printing labels completed onsite enable semiconductor manufacturers to create specialized labels on demand that are resistant to heat and abrasion, while also being small and detailed enough to fit onto tiny, complex components. This level of precision is essential for accurate tracking and identification throughout the production process, particularly in environments where even minor errors can lead to costly downtime or defects.

Pharmaceutical and biotech industries

Thermal printing labels completed onsite allow companies in the pharma and biotech industries to print labels in real-time, ensuring they can meet regulatory demands and adjust information as needed. Expiration dates, batch numbers, and specific testing information, for example, can be updated on the fly, which is especially important for ensuring traceability and maintaining the chain of custody in clinical trials or drug manufacturing. The ability to print variable data onsite also helps pharmaceutical companies respond quickly to regulatory updates, avoiding delays and ensuring compliance with the latest guidelines.

Automotive industry

From engines to electronic components, automotive parts are often exposed to extreme heat, chemicals, and mechanical stress. Thermal printing labels completed onsite allow automotive manufacturers to create durable, heat-resistant labels that remain legible and intact throughout the production process and beyond. Additionally, the industry’s need for variable data labeling — such as serial numbers, part identification, and manufacturing dates — can be met efficiently through onsite printing, ensuring that each part is accurately tracked from assembly to final inspection.

Food and beverage sector

Thermal printing labels completed onsite provide food and beverage manufacturers the ability to quickly update labels in response to changing product lines or regulatory requirements, ensuring that information remains accurate and compliant. This flexibility is crucial in an industry where product life cycles are short, and labeling errors can result in costly recalls or health risks, and the durability of thermal printing labels allows them to remain legible through the cold storage and mechanical abrasion often present in food and beverage processing.

Oil and gas industry

The oil and gas industry operates in some of the most harsh environmental conditions, where equipment and labels must withstand exposure to extreme temperatures, chemicals, and rough handling. Labels on pipelines, equipment, and storage containers must be durable, legible, and up-to-date to ensure safety and compliance. Thermal printing labels completed on site allow companies to produce customized labels that are resistant to these tough conditions, with materials that are designed to endure long-term outdoor exposure and physical wear. 

How to choose the right thermal printing label for your needs

Really, the right thermal printing label isn’t something you choose. It’s something you design.

There are a lot of variables that must come together in just the right combination for a label to work efficiently and reliably in your research, manufacturing, or processing environment. And the only way to make sure that combination is exactly right is to use a custom label designed by labeling experts in your industry.

CleanMark has 40 years of experience providing labeling solutions to high-tech industries that are just as innovative as the products our customers are producing. Our experienced label-engineers work with you to understand the specific needs of your use-case, then they design a label tailored to your unique needs.

Ready to up your process efficiency with custom thermal printing labels? Schedule a consultation with one of our label engineers today.