How to Find the Perfect Print Resolutions for your Barcode Label Size

Your barcode labels elevate your operational efficiency. The data encoded into the little symbol can be used to expedite accurate picking and shipping, prevent product tampering and counterfeiting, tighten inventory control, minimize the impact of a product recall, streamline audits, and give you real-time visibility into your enterprise data.

You get all that with one small label. Choosing the right combination of barcode label size and print resolution is critical to ensuring your labels deliver on all counts.

The print resolution reflects the number of dots per inch (dpi). The higher the dpi, the sharper the definition of the image. Thermal printers range from 203 to 600 dpi. The smaller the label, the higher the resolution you will require to produce a scannable image. Micro-labels are used to identify tiny components, like those in electronics and medical devices. For these labels to be easily scanned, the micro-label requires high resolution and tight registration. A 600 dpi thermal printer is essential if you are producing barcodes that are less than .25” x .25”, fonts that are less than 10 point, or regulatory symbols or text that is smaller than 6 point.

Zebra, the worldwide leader in thermal print solutions, manufacturers a complete portfolio of barcode printers. They’ve just introduced the ZT600 industrial printers, a series that replaces the gold standard set by the Zebra Xi4 series. The ZT600 is designed for heavy-duty performance in a harsh environment, like a manufacturing facility or warehouse. The ZT610 prints 600 dpi on labels as small as 3 mm. Other Zebra industrial printers, like the ZT410, offer the option of high-resolution printing.

For larger barcode labels—like shipping labels—203 dpi resolution will suit your applications. The video below from Zebra Technologies offers additional tips for choosing the best print resolution for your application.

If you’re not sure of the best label size and print resolution, talk to us at Informs. We’ll help you understand your choices so you get the best match.