Comparison Guide
Linerless vs Die-Cut Labels
A comprehensive comparison to help you choose the right label technology for your business
Quick Decision Guide
Choose Linerless
High-volume operations prioritising efficiency and sustainability
- You print thousands of labels daily
- Waste reduction is a priority
- You need variable label lengths
- You want fewer roll changes
Choose Die-Cut
Lower volumes or when using existing standard printers
- You have existing non-linerless printers
- You print fewer than 500 labels per day
- You need specific die-cut shapes
- Initial equipment cost is a concern
Side-by-Side
Detailed Comparison
| Factor | Linerless | Die-Cut |
|---|---|---|
| Waste per 1,000 labels | 0g - no backing waste | ~150-200g liner waste |
| Labels per roll (same diameter) | Up to 40% more | Standard quantity |
| Roll changes per shift | Fewer changes needed | More frequent changes |
| Storage footprint | Compact - 50% less space | Larger warehouse space needed |
| Label length flexibility | Variable - any length | Fixed sizes only |
| Printer compatibility | Requires linerless-ready printer | Works with any thermal printer |
| Environmental impact | Lower carbon footprint | Higher due to liner production/disposal |
| Cost per label (high volume) | Lower total cost of ownership | Higher when including disposal costs |
indicates advantage for that label type
In Detail
Understanding the Differences
500kg+
Annual waste eliminated per high-volume printer
Waste Reduction
The most significant difference between linerless and die-cut labels is waste. Traditional labels generate approximately 150-200 grams of liner waste per 1,000 labels printed. This backing material is coated with silicone to prevent the adhesive from bonding, making it non-recyclable through standard waste streams. For a business printing 10,000 labels per day, that's 1.5-2kg of non-recyclable waste daily, or over 500kg annually. Linerless labels eliminate this waste entirely.
30min+
Labour saved per shift from fewer roll changes
Operational Efficiency
Roll changes interrupt workflows and require operator time. With 40% more labels per roll, linerless significantly reduces these interruptions. In a typical QSR environment with multiple printers running continuously, this can save 30+ minutes of labour per shift. The variable-length capability also eliminates the need to stock and manage multiple label SKUs, simplifying inventory and reducing stockout risks.
2,000+
Labels/day where linerless typically becomes more cost-effective
Cost Analysis
While linerless labels may have a similar or slightly higher unit cost than traditional labels, the total cost of ownership is typically lower for high-volume operations. Savings come from: fewer rolls purchased (40% more labels per roll), reduced labour for roll changes, lower storage costs (50% space reduction), and eliminated liner disposal fees. The breakeven point varies by volume but typically favours linerless above 2,000 labels per day.
3
Key printer features needed for linerless
Equipment Considerations
Linerless labels require printers with three key features: a linerless cutter (guillotine or rotary), a special platen roller with non-stick coating to prevent adhesive buildup, and appropriate label sensing (black mark or length-based rather than gap detection). Most major thermal printer manufacturers now offer linerless-ready models: Star Micronics, Epson, Bixolon, SATO, and Zebra all have compatible options. If you're purchasing new printers, specifying linerless capability adds minimal cost.
Getting Started
Switching from Die-Cut to Linerless
Audit Your Printers
Check if your current printers are linerless-capable or can be upgraded. Use our hardware picker tool to verify compatibility.
Learn moreCalculate Your Volumes
Estimate your daily/monthly label usage across all printers. Higher volumes see faster ROI from linerless.
Request Samples
Test linerless labels with your printers and applications before committing. We provide free samples for evaluation.
Learn morePlan Roll-Out
Consider a phased approach: start with highest-volume printers to maximise early savings and learn operational adjustments.
Questions Answered
Frequently Asked Questions
Can I use linerless labels in my current printer?
Are linerless labels more expensive than die-cut?
What happens to the backing liner from die-cut labels?
Can linerless labels print the same quality barcodes?
How do I know which width linerless labels I need?
Is there a minimum order for switching to linerless?
Ready to Compare for Yourself?
Request free samples of both label types to test with your specific printers and applications. Our team can help you calculate potential savings based on your volumes.