Troubleshooting Thermal Transfer Printing Problems
Troubleshooting Thermal Transfer Possible Cause
Printing Problems
Poor Edge Definition (bar codes and Print speed is too high
alphanumerics)
Ribbon and media are incompatible
Bar Codes Smearing (bar code edges Printhead energy setting is too high
"bleeding" or "feathering")
Print speed is too high
Rotated ("ladder" style) bar code is being used
Bars in Bar Codes Are Too Wide or Too Print speed is too high
Narrow Resulting in a Poor Scan Grade
Printhead energy setting is too high/too low
Underburn (not enough ribbon transfer)
Overburn (too much ribbon transfer)
Bars too thick
Insufficient Print Contrast: Bars Are Not Dark Label surface is too dark to provide proper contrast
Enough, Spaces Are Not Light Enough between bars and background
Printhead energy setting is too low
Printed Image is Full, but Greyish or Printhead energy setting is too high
"Translucent"
Printhead pressure is too high
Ribbon and media are incompatible
Voids in Printed Image: Areas Where There Is Dust on label
No Print
Tag or label surface is inconsistent (including colour
flood coating)
Ribbon and media are incompatible
Printhead elements or "dots" are dirty or obstructed
Printhead elements or "dots" are burned out
Printhead misalignment
Repetitive Voids in Image Printhead elements or "dots" are dirty or obstructed
Printhead elements or "dots' are dirty or obstructed
Printhead elements or "dots" are burned out or worn
down
Streaks or "Dead Spots" in Printed Image Ribbon is wrinkled
Poor coating quality on tag or label surface
Printhead elements or "dots" are dirty
Corrective Action
Reduce print speed; do not rotate symbol
Test alternative ribbon or media
Reduce energy setting until bar edges are
clean
Reduce print speed
Change label design to include only
normal ("picket fence" style) bar codes
Reduce print speed
Adjust to optimize average bar growth
(visually or with verifier)
Increase printhead energy setting or use a
ribbon with higher sensitivity (refers to
ribbons requiring less energy)
Reduce printhead energy setting or use a
ribbon with lower sensitivity (refers to
ribbons requiring more energy)
Reduce printhead energy setting
Choose label with lighter surface colour
Increase printhead energy setting
Reduce energy setting
Reduce printhead pressure
Test alternative ribbon or media
Remove dust with compressed air. Place
static tinsel across label unwind
Choose face sheet or flood coating inks
specifically designed for thermal transfer
Test alternative ribbon or media
Clean printhead with presaturated
cleaning card or soft-stemmed Q-tip and
isopropyl alcohol
Replace printhead
Check for alignment-related defects with a
known well-performing ribbon/media
combiniation; realign if necessary
Clean printhead with presaturated
cleaning card or soft-stemmed Q-tip and
isopropyl alcohol
Clean printhead with presaturated
cleaning card or soft-stemmed Q-tip and
isopropyl alcohol
Replace printhead
See Ribbon Wrinkling
Contact media supplier for assistance
Clean printhead with presaturated
cleaning card or soft-stemmed Q-tip and
isopropyl alcohol
 Troubleshooting Thermal Transfer Printing Problems
Troubleshooting Thermal Transfer Possible Cause
Printing Problems
Not Printing Any Image (or barely any image) Ribbon is loaded backwards
Ribbon and media are incompatible
Ribbon Wrinkling Printhead is misaligned
Guide-bar is misaligned
Printhead energy setting is too high
Rewind tension is greater than unwind tension
Ribbon is feeding unevenly
Label liner is migrating out of feed path
Ribbon rewind shaft is out of alignment
Printhead pressure is too high
Ribbon is too narrow or wide for media
Ribbon Breaking Printhead elements or "dots" are dirty or obstructed
Obstruction in ribbon feed path
Printhead energy setting is too high
Printhead pressure is too high
Printer set on direct thermal mode
Unwind tension is too high
Backcoat - not there/insufficient
Ribbon Slippage: Ribbon and Label Not Rewind tension is too low
Advancing at the Same Rate
Ribbon is sticking to printhead
Label surface is too slick for ribbon
Unwind tension is too high
Excessive Sticking Between Ribbon and Label Printhead energy setting is too high
Printhead pressure is too high
Angle at which label is exiting the printer is too steep
Excessive Noise During Printing Printhead energy setting is too high
"Strip plate" on printer
Die-Cut Labels Continue to Feed Without Label sensor is dirty or obstructed
"Calibrating"
Printer is set in "continuous" mode
Corrective Action
Use tape to determine "ink side" of ribbon
(ink will come off on tape). Then make
sure ink side of ribbon is facing the media
surface as it feeds through printer
Test alternative ribbon or media
Realign printhead
Realign guide-bar
Reduce printhead energy setting
Adjust tension (unwind should be greater
than rewind)
Remove supply roll and used ribbon from
take-up shaft; reload ribbon making sure
film is feeding straight to rewind shaft not
pulling in one direction
Make sure label roll is flush against printer
on label roll bar and label guide bar is up
and just beyond outside edge of label liner
Service required to realign or replace
ribbon rewind shaft
Reduce printhead pressure
Make sure ribbon width is equal to, or
slightly greater than, media width
Clean printhead with presaturated
cleaning card or soft-stemmed Q-tip and
isopropyl alcohol
Check for and remove label, tag or other
particles from feed path and printhead
assembly
Reduce printhead energy setting
Reduce printhead pressure
Set printer to thermal transfer mode
Reduce unwind tension
Replace ribbon and contact your ribbon
supplier
Increase rewind tension
Clean printhead with presaturated
cleaning card or soft-stemmed Q-tip and
isopropyl alcohol
Test different ribbon grades or change to
a matte-coated label stock in place of
gloss
Reduce unwind tension
Set energy setting as low as possible
while still achieving acceptable print
quality
Reduce printhead pressure
Adjust angle down
Reduce printhead energy setting
Lower strip plate is not adjusted properly
Clean sensor with soft-stem Q-tip and
isopropyl alcohol or compressed air
Change setting to "label" mode in label
software
 Troubleshooting Thermal Transfer Printing Problems
Troubleshooting Thermal Transfer
Printing Problems
Printer Doesn't Stop When Out of Ribbon
Printer Stalls or Will Not Print
Printer is in "Label" mode and you are running
"continuous" material
Trouble Removing Used Ribbon From Take-up Rewind tension is too high
Shaft
Premature Printhead Failure
Possible Cause
Die-cut label length is less than minimum length for
specific printer model
Label sensor may not be aligned properly with gap
between die cut labels
Ribbon sensor is dirty or obstructed
Ribbon sensor is out of position
Ribbon "trailer" is incorrect for specific printer model
Ribbon or media are not loaded properly (missing
sensor)
Ribbon ink density is too light to be "seen" by ribbon
sensor
Ribbon or media sensors are dirty or obstructed
Label liner is too opaque to be "seen" by label gap
sensor
Excessive thermal stress
Printhead pressure is too high
Insufficient printhead maintenance
Rewind tension is too high
Label surface is uneven (containing a hologram or raised Without a label design change, the edges
area)
Ribbon width is not covering media width
Corrective Action
Change to a "two-up" format
Realign label sensor
Clean sensor with soft-stem Q-tip and
isopropyl alcohol or compressed air
Align sensor properly
Contact your ribbon supplier to confirm
that the correct trailer is attached
Reload ribbon and media, making sure
both pass under respective sensors
Consult printer manual or contact printer
manufacturer or VAR for instructions on
calibrating sensor
Clean sensors with soft-stemmed Q-tip
and isopropyl alcohol or compressed air
Consult printer manual or contact printer
manufacturer or VAR for instructions on re-
calbrating sensor, or contact label
manufacturer for liner alternatives
Change media type to "continuous" on
printer or in label software
Reduce rewind tension and/or begin using
empty cores on rewind shaft as take-up
cores
Make sure printhead energy is set as low
as possible while still printing an
acceptable image
Choose thinner gauge media or reduce
printhead pressure
Printheads must be cleaned after every
ribbon or media roll change. Use a pre-
saturated cleaning card or a soft-stemmed
Q-tip or cotton cloth dipped in isopropyl
alcohol. The inside of the printer,
including parts along the media feed path,
must also be wiped down using a slightly
damp cotton cloth to eliminate plastic label
liner dust which is drawn to the printhead
while the machine is running and can fuse
to printhead surface causing elements to
burn out
Reduce rewind tension
of the raised surface will abrade the
printhead more quickly than the rest of the
label surface will
Make sure ribbon width is equal to or
slightly greater than media width