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Step-by-Step Guide

How to Load Linerless Labels

Step-by-step guide for loading linerless thermal rolls correctly every time

Loading linerless labels requires slightly different handling than traditional die-cut labels. This guide covers the universal process and printer-specific variations to ensure optimal print quality and minimal jams.

What You'll Need

  • Linerless-ready printer with silicone-coated platen roller
  • Non-stick cutter blade (guillotine or tear bar)
  • Linerless thermal rolls (correct width for your printer)
  • Clean, lint-free cloth for roller maintenance

Step-by-Step Instructions

  1. 1

    Power off the printer

    Switch off the printer and unplug it from the power source. This prevents accidental activation during loading and protects both you and the printer mechanism.

    Tip: Wait 10 seconds after powering off to let any residual charge dissipate.
  2. 2

    Open the printer cover

    Release the cover latch and open the printer fully. On most models, press the release button on the side or front of the printer. The cover should swing open to reveal the paper path and platen roller.

    Tip: Some Star and Epson models have a top-loading design; others load from the front.
  3. 3

    Remove any existing roll

    If there's an old roll installed, remove it completely. Check for any paper scraps or debris in the paper path, especially around the cutter mechanism and platen roller.

  4. 4

    Clean the platen roller

    Use a lint-free cloth dampened with isopropyl alcohol to clean the silicone-coated platen roller. Rotate the roller manually while cleaning to cover the entire surface. This removes adhesive residue that can cause print quality issues.

    Tip: Clean the roller every 3-5 roll changes for best results. Never use acetone or harsh solvents.
  5. 5

    Insert the new linerless roll

    Place the roll in the paper bay with the thermal-coated side facing up (toward the print head). The roll should unwind from the bottom, feeding paper up and over the platen roller. Ensure the roll sits flat and centred.

    Tip: Check the roll direction—if prints come out blank, the roll is likely inserted backwards.
  6. 6

    Thread the paper through the cutter

    Pull approximately 10cm of paper through the paper path, past the platen roller and through the cutter mechanism. Ensure the paper lies flat without creases or bunching at the edges.

  7. 7

    Close the cover and test

    Close the printer cover firmly until it clicks. The cover should close smoothly without trapping paper. Power on the printer and run a test print or self-test to verify proper loading and print alignment.

    Tip: Most printers will auto-feed and cut when powered on with a new roll.
  8. 8

    Calibrate if needed

    If your printer has gap sensors (for die-cut labels), you may need to disable them or switch to continuous mode for linerless rolls. Consult your printer manual for sensor calibration settings.

Printer-Specific Notes

While the general process is similar across all linerless-ready printers, here are brand-specific tips:

Star Micronics

TSP143IIIU, TSP654II, mC-Print3
Star linerless printers auto-detect roll width. Use Star Configuration Utility to set paper type to 'Linerless' and adjust cut position. Top-loading design makes roll changes quick.

Epson

TM-L90 Liner-Free, TM-T88VI-iHub
Epson models require setting the DIP switches or using APD utility to configure for linerless mode. Ensure the 'liner-free' platen roller is installed (part number varies by model).

Zebra

ZD421d, ZD621d (with linerless kit)
Zebra desktop printers need the linerless platen roller kit installed. Configure media type as 'Continuous' in ZPL commands or via Zebra Setup Utilities. Disable gap/mark sensors.

Bixolon

SRP-S300, SRP-S3000
Bixolon S-series printers are purpose-built for linerless. Use Bixolon Label Artist or mobile SDK to configure label length. Auto-cutter settings can be adjusted via command or DIP switch.

SATO

FX3-LX
SATO linerless models support both continuous and mark-sensed linerless media. Configure via SATO All-In-One Tool. Unique 3-inch width option available for retail applications.

Troubleshooting Common Issues

Paper jams frequently

Cause

Adhesive buildup on platen roller or incorrect paper path threading

Solution

Clean the platen roller with isopropyl alcohol. Ensure paper feeds smoothly without bunching at the edges. Check that the cutter blade is clean and undamaged.

Blank prints (no image)

Cause

Roll inserted backwards (wrong side facing print head)

Solution

Remove the roll and reinsert with thermal-coated side facing up toward the print head. Test by scratching the paper surface—the thermal side will darken slightly with heat friction.

Partial or faded printing

Cause

Dirty print head or incorrect print darkness setting

Solution

Clean the print head with a thermal head cleaning card or isopropyl alcohol. Increase print density/darkness in printer settings. Check that the roll is a quality linerless thermal media.

Labels stick to each other on the roll

Cause

Poor quality media or storage in high humidity/heat

Solution

Use reputable linerless rolls with proper silicone release coating. Store rolls in cool, dry conditions (15-25°C, below 65% humidity). Avoid direct sunlight.

Incorrect cut length

Cause

Printer not calibrated for linerless continuous mode

Solution

Disable gap/mark sensors and configure for continuous media. Set the desired label length in printer settings or via print commands. Run a calibration routine if available.

Adhesive residue on printer surfaces

Cause

Normal occurrence with linerless media over time

Solution

Clean all paper path surfaces, platen roller, and cutter regularly. Use dedicated linerless-ready equipment with non-stick coatings. Schedule maintenance every 10-15 roll changes.

Frequently Asked Questions

Can I use linerless labels in any thermal printer?

No. Linerless labels require printers with silicone-coated platen rollers and non-stick cutter mechanisms. Standard thermal printers will jam due to the exposed adhesive. Always use linerless-ready or linerless-certified printers.

How do I know which side of the paper is the print side?

The thermal-coated (print) side is usually smoother and slightly shinier. You can test by gently scratching the surface with a fingernail—the thermal side will produce a faint grey mark from the heat friction.

How often should I clean the platen roller?

For optimal performance, clean the platen roller every 3-5 roll changes, or immediately if you notice print quality degradation or paper feeding issues. High-volume environments may require more frequent cleaning.

What happens if I use the wrong roll width?

Using rolls wider than your printer's capacity will cause jams. Narrower rolls may print but with misaligned content and potential edge feeding issues. Always match roll width to your printer's specifications.

Do linerless labels work in cold environments?

Most linerless adhesives perform well between 5°C and 35°C. In refrigerated environments (cold rooms, fridges), allow the printer and labels to acclimate and consider cold-rated adhesive formulations for freezer applications.

Related Resources

What is Linerless Labeling?

Learn how linerless technology works and its benefits.

Shop Linerless Rolls

Browse our range of BPA-free linerless labels by width.

Roll Compatibility Matrix

Find compatible roll sizes for your printer model.

Linerless vs Die-Cut Labels

Compare linerless and traditional die-cut labels.

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