When it comes to labels, we all have been using barcode, RFID, and even simple labels and stickers that have some sort of adhesive backing, haven’t we? After necessary printing, just peel off the release coating of the label and stick it to the intended package. These are called liner labels. However, there are other kinds of labels too, that don’t come with a paper backing. With the labels, you just stick the label as it comes out of the printer. With growing environmental concerns and the adoption of climate-conscious business practices, many major retail, warehousing, healthcare, manufacturing, and logistics firms are now switching to these kinds of linerless labels.
Let’s see what a linerless media is and the necessary hardware and software required to make better use of them in detail.
Liner and Linerless Labels: The Difference
As the name suggests, liner labels and linerless labels have only one difference: the presence of a backing material. Traditional liner labels consist of three layers: printable face stock, adhesive, and a silicone-coated release liner. Once printed, the user peels the label from the liner and applies it to the package.
However, linerless labels eliminate the liner entirely. Instead, the labels are coated with a special release layer on the top surface and pressure-sensitive adhesive on the bottom. This means the labels do not stick to the roll itself but remain ready for immediate application once printed.
The result? More labels per roll, less waste, and faster labeling operations.
At a glance, the only distinction between the two media is the presence of a liner—but technically, the implications are significant:
• Liner Labels:
a.Use silicone-coated backing paper.
b. Generate waste after every label application.
c. Limited roll capacity (liner adds bulk).
d. Compatible with standard label printers.
• Linerless Labels:
a. No backing liner.
b. Use a silicone top coating that allows labels to be wound in rolls without sticking.
c. Higher roll capacity (up to 40% more labels per roll).
d. Require linerless-compatible printers with special cutter mechanisms and sensors.
This single design change translates into measurable improvements in sustainability, efficiency, and cost savings.
Why Linerless Labels for Retail, Warehousing, and Logistics?
While liner labels are the norm in retail, warehousing, and logistics as well as healthcare and manufacturing industries, there are certain advantages to adopting linerless labels in the biggest label consumption areas like retail and supply chain.
Some of these advantages are:
1. Sustainability and Waste Reduction with Linerless Labels
Every liner label roll produces waste equivalent to the backing paper. In high-volume environments like e-commerce warehouses or retail chains, this waste piles up to tons of paper annually, which should be avoided. Linerless label eliminates liners completely, helping companies meet ESG (Environmental, Social, Governance) and climate-conscious goals.
2. Higher Roll Capacity = Less Downtime
A linerless roll carries 30–40% more labels than a traditional roll of the same diameter. It translates into fewer roll changes, less operator intervention, and improved uptime in fast-moving supply chains.
3. Safety and Cleanliness with Linerless Labelling Practices
Discarded liners create clutter around packaging stations and increase the risk of slips and falls in warehouses. Removing the liner reduces both clean-up costs and workplace hazards.
4. Flexible Label Lengths
Unlike pre-cut liner labels, linerless media allows variable label lengths to be printed on demand, reducing inventory complexity (fewer SKUs for different label sizes) and supporting dynamic printing needs, such as shipping labels with varying content density.
Linerless Printing Solutions by Zebra Technologies
Zebra Technologies, a leader in RFID, Barcoding, and labeling solutions, has developed a dedicated range of linerless-ready desktop and mobile printers.
Technical Features of Zebra Linerless Printers:
1.The popular Zebra Linerless desktop printer is the Zebra ZD611, ZD621 and the Mobile printer is the ZQ320 printer. Zebra has been offering linerless printing solutions, printers, and linerless label rolls for over a decade and has been helping businesses reduce waste.
2. The Zebra Technologies’ ZD611 and ZD621 linerless models are specifically designed and tested for use with Zebra ZeroLiner labels.
3. Specialized Printhead & Platen Rollers are designed to prevent adhesive build-up.
4. Enhanced Cutters- Rotary or guillotine-style cutters hardened for linerless media.
5. Smart Sensors- Detect label presence and length, adjusting feed accordingly.
6. Software Integration- ZebraDesigner and Print DNA software suite for optimizing print formats and minimizing media waste.
7. Shipping labels, food labeling in quick-service restaurants (QSRs), and logistics compliance labeling.
Linerless Label Printers by TSC/Printronix
TSC/Printronix Auto ID also offers robust linerless printing solutions for enterprise environments.
Technical Highlights of TSC Linerless Printers:
1.Popular linerless printer models from TSC include the TSC DA Series, TDM Series 2-inch (TDM 20) and 3-inch (TDM 30) printers, and Alpha-2R mobile printers, all available in linerless-ready versions.
2. Durable Print Mechanisms, engineered to handle continuous, adhesive-backed printing without clogging.
3. High-Capacity Roll Handling; optimized for larger linerless rolls to extend operational runtime.
4. Eco-Friendly Printing Modes that reduce energy consumption while maintaining print quality.
5. Integration Flexibility with compatibility with SAP, Oracle, and other ERP/WMS systems.
6. Versatile Applications, including courier parcel labels, inventory tracking, healthcare wristbands, and warehouse rack labeling.
Hardware and Software Requirements for Linerless Printing
To successfully adopt linerless technology, businesses need to make some changes to their existing printing solutions, starting with procuring linerless printers and label rolls.
1.Must have printers that are linerless-certified with specialized cutters and anti-stick coatings.
2. Get linerless rolls with silicone top coating and pressure-sensitive adhesive.
3. For managing variable label lengths and formats, get label design software (e.g., BarTender, ZebraDesigner).
4. Ensure periodic cleaning of printheads and platen rollers to ensure long-term performance.
In summary, linerless printing is not just an incremental improvement but a paradigm shift in labeling technology. With sustainability pressures, operational inefficiencies in liner disposal, and the rising demand for adaptable labeling in omnichannel retail and logistics, linerless solutions are fast becoming the industry standard.
As a leading supplier of RFID and barcode labels, printing media, and linerless and lined printers from Zebra and TSC/Printronix, we suggest businesses should invest in Zebra and TSC linerless printers to ensure faster workflows, reduced environmental impact, and long-term cost efficiency.
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