Basic Differences Between Thermal Printer and Inkjet Printer

Basic Differences Between the Two Label Printers

Thermal printers use a system that transfers heat to heat-activated label material, called direct thermal, or uses a ribbon (wax or resin), called thermal transfer. This heat transfer on the label surface or through the ribbon creates the image. It is the most popular and widely used label printing method in the world today. This combination replaced the slower laser and dot matrix printers of the late 20th century. Thermal printing is the fastest and lowest-cost method today, used for barcode labels and various variable image labels.

Inkjet technology (full-color printing) has improved significantly over the past five years and is becoming a viable alternative to thermal. Inkjet printing is faster than earlier versions and produces highly durable prints, durable enough to withstand liquids and chemicals. The biggest advantage is the striking colors.

Multiple colors have created opportunities for advertising in entirely new ways. Epson, VIP, Afinia, and other inkjet printers use light-resistant, UV-resistant, and waterproof inks to create microdots of ink on highly durable roll-to-roll label material, now available in matte and glossy finishes.

Another advantage of inkjet is high resolution. These printers can print durable, very small fonts and high-quality graphics. This is important in any industry where unreadable instructions or icons could lead to litigation.

Comparing Inkjet and Thermal printers

Compared to standard shipping labels or UPC labels, inkjet label material and inkjet cartridges cost approximately 5 to 7 times more than thermal transfer or direct thermal. The advantage is the ability to capture customers' attention with dazzling colors.

Compared to creating full-color labels with a printer, inkjet printing costs can be 5 to 10 times lower. You can also print exactly what you want, when you need it. Color print manufacturers can take 4 to 6 weeks. When comparing short-run, full-color labeling requirements between inkjet and color print manufacturers, inkjet is the best choice.

Inkjet is ideal for product labels, GHS warning labels, small, complex hazard or highly durable labels, and labels where you can capture customers' attention with a quote.

Basic cost difference: Thermal printers are designed to print millions of labels on a single printhead, with an average price of 1 to 3 cents per label.
Example: 4×6 direct thermal, 3” core, 8” OD, matte labels cost $0.017 per label for 1,000, and synthetic labels cost $0.182 per label (excluding ribbon cost).
Example: 4×6 Epson color labels, 2” core, 4” OD, matte labels cost $0.41 per label for 950, and glossy labels cost $0.73 per label.

Quick cost per sheet (100,000 sheets as an example):
Direct thermal paper: 1.7¢ label + 0 ribbon = 1.7¢/sheet
Thermal transfer synthetic: 18.2¢ label + 0.27¢ ribbon = 18.5¢/sheet
This is still less than 1/2–1/4 of inkjet color (41–73¢/sheet).

Productivity and Maintenance： Industrial models offer 24/7 continuous printing, with a printhead life of 3–5 million pages and a replacement cost of $295. $;
No drying time, no risk of clogging, and downtime approximately 1/10 that of inkjet.

Printer output: Comparing inkjet print volume to thermal print volume can be tricky. If you use direct thermal labels, there are no ribbon costs. If you use thermal transfer labels, the cost of the ribbon will vary.

Thermal Printer

● Monochrome (black) or pre-printed color base; thermal transfer printing can produce multiple colors
● Label resolutions available in 203, 300, or 600 dpi max
● Monochrome (black) or pre-printed color base; thermal transfer printing can produce multiple colors but requires changing the ribbon
● Direct thermal printing eliminates waste; recyclable ribbon cores are VOC-free
● Cost: $0.02–$0.20 per label

Inkjet Printer

● Full color CMYK + white/varnish (UV model)
● Requires a combination of synthetic media and UV ink or lamination; otherwise, blurring is likely to occur.
● Printhead cleaning, ink cartridge replacement, and waste ink tank are required.
● Waste cartridges and ink require hazardous waste disposal; some VOC emissions are generated.
● Cost: $0.45–$0.75 per print.

Inkjet Printer VS. Thermal Printer: How to Choose?

Thermal Printing: If your business prints shipping, internal, pricing, or data labels for indoor use or short-term exposure to heavy or light weather, you need a thermal printer. If you require color indicators, logos, or warnings on your labels, simply preprint them for annual usage and use the same label format.

Color Inkjet Printing: Color thermal inkjet has found a home for many new startups. For businesses that produce multiple products, flavors, or brands and need color product labels, inkjet printers are a great choice. Even established businesses with test product launches or smaller, specialized runs can find use for inkjet printers. Another significant demand we see is in the chemical and pharmaceutical industries. Many large companies have switched from preprinted red GHS labels to custom colors for drum labels, freezer applications, and durable shipping labels.

Quick Takeaway:
"For eye-catching color and instant printing for short runs—choose inkjet.
For cost-effective, durable, and long-run orders in the millions—choose thermal.

As you've learned, each label printer has its own strengths and weaknesses, making it suitable for specific labeling applications. You'll need to weigh the different features of these printers and determine which one to choose based on your business needs and usage scenarios. Once you've decided on your preferred printer, the next step is to compare different printer models and brands and make the best choice.

Thermal Printer Brands Recommened

Hoin thermal printers Manufacturer & Supplier From China

Hoin thermal printers are easy to use and widely used across various industries. Their rich interfaces and comprehensive functionality have earned them global popularity and made Hoin a renowned thermal printer manufacturer.

As one of the world's leading printing equipment manufacturers, Hoin printers are sold in over 80 countries and regions. Through years of research, innovation, and technological advancement, the company has spearheaded the development of group standards for the printing industry. As a leader in enterprise standards in the printing sector, Hoin offers a comprehensive and professional full-process printing solution, providing ecosystem partners with information connectivity in the IoT era. Hoin plays a key role in the automation, intelligence, and networking of data input and output technologies across various industries. Our comprehensive product line encompasses professional printing products ranging from chips to complete machines, from 2D to 3D, from commercial to consumer, from industrial to portable, from black and white to color, and from traditional to intelligent printing. Our products cover the entire printing process, from information collection to data output.