Zebra Printer Barcodes look smeared

Possible Causes:

• Zebra Printer printing "Ladder" style barcodes
• Zebra Printer speed is too high
• Zebra printer heat is too high
• Zebra printer is dirty.
• Zebra Printer label stock requires fine tuning
• Barcodes are too fine.

Zebra Printer printing "Ladder" style barcodes

What is a "ladder" style barcode. When you stand in front of your Zebra printer and the label is hanging out towards the floor. If the Barcodes look like a ladder, then they are oriented to be produced one line at a time. (like climbing a ladder) This is a more difficult task for any thermal printer (not just a Zebra printer). Picket fence barcodes are produced in such a way as to allow the print head to produce better quality. When you are standing in front of your Zebra printer with your label hanging towards the floor this barcode looks like a picket fence. The print head elements are now on throughout the printing of the barcode allowing the quality to be optimized.  When possible, orient your label designs to take full advantage of picket fence barcodes. Half of the warehouses that are printing labels have smeared ladder barcodes.

Zebra Printer speed is too high, Zebra printer heat is too high, Zebra printer is dirty

These three items are all inter-related. Start by cleaning the printer with Alcohol, decreasing the heat and slowing the printer down. Work your way up from there. Although your Zebra printer may be capable of printing at 12"/second, printing a ladder barcode at that speed is another matter altogether. Start down at 4"/second with lower heat. Clean the printer. If the quality looks good slowly add speed (6"/second). If the barcode fades, add a little heat. As soon as you see waves on the side of the barcode you have reached your limit.  Note: AIAG labels can be printed both landscaped or portrait to eliminate ladder barcodes.

Zebra Printer label stock requires fine tuning

Synthetic stocks can represent a further challenge because they require a better understanding of all of the adjustments covered in the above section. Resin ribbons that are used on most synthetic labels require more heat and leave less room for error or for dirty printers. Definitely consider running these labels at a slower speed.

Barcodes are too fine

5 mil barcodes printed on synthetic stocks printed ladder style are hard to achieve. You can do it if you stand guard by your Xi series Zebra printer and maintain it well. The finer the barcode the more likely the bars will merge. Consider removing digits from your barcode to increase its size. Call us for ideas. (switch symbologies or use a database "look up")