Print Without Interruptions: Tips to Prevent Paper Jams and Boost Printing Efficiency

In the printing industry, paper jams are an occasional challenge that no one wants to encounter. Often caused by imperfections in the label material, these disruptions can slow down production. In this blog, we’ll explore the reasons behind paper/printer jams and share effective strategies to ensure a smoother and more efficient print flow.

Paper Jams Got You Stuck? Here’s What’s Really Going On:

1. Improper Label Alignment:

To ensure consistent output, printing requires a smooth, aligned transition as labels advance through the printer. Labels that come on a roll can be wound too tight, too loose, or misaligned, resulting in uneven tension or wrapping.  This can cause labels to stick together or bunch, leading to printer jams.

The smooth transition of fan-folded media requires a neat stack of labels positioned directly behind the printer at the correct level. When positioned properly, the labels will move seamlessly through the printer without any unnecessary tension.

2. Label Material Quality:

For seamless printing and optimal print quality, it’s important to choose high-quality label material. Manufacturing labels with lower-quality materials can result in occasional label imperfections, such as wrinkles, creases, or inconsistent thickness. These flaws increase friction and tension as the labels advance through the roller mechanism, potentially causing jams.

3. Incorrect Printer Settings:

It’s important to become familiar with the printer settings and how to adjust for different label material specifications.  Incorrect settings can cause the printer to mishandle the material.

When using different types of label materials and sizes, calibration might be warranted. Most printers have the ability to run a simple calibration of the labels to ensure proper gap detection and print placement.  If the printer settings do not match the label roll or fan fold requirements, improper feeding can occur, resulting in a jam.

4. Adhesive and Static Issues:

Printers have a maximum media thickness that must be adhered to for smooth media movement through the printer. If the media thickness is not compatible with the printer, friction can occur, causing irregular progression and jamming.  

Static can increase when label materials (such as film, paper, or adhesives) repeatedly contact and separate during unwinding, rewinding, or movement through the printer. This friction generates static electricity, causing the labels to stick together, potentially blocking or jamming the media.

5. Humidity Exposure:

Label performance can be significantly impacted by humidity levels. If you're experiencing label jams during printing, low humidity may be the culprit. In dry environments, labels can shrink, curl, and lose dimensional stability. These changes can disrupt the printing process, as the label curls at the edge, a barrier is created that the print head cannot pass through.

Labels affected by humidity can be salvaged. We recommend allowing the labels to sit in an opened box for 12-24 hours to acclimate to the changes in humidity.

While paper jams are inevitable, taking proactive steps can significantly reduce these frustrating disruptions. To maintain a streamlined and efficient printing operation, it’s crucial to understand the many factors that influence label and printer compatibility. When jams occur, minimize frustration by quickly assessing the potential causes, including alignment and media quality to printer settings and environmental elements. Implementing the simple solutions discussed in this blog will minimize downtime, improve print quality, and ensure a smoother, more reliable print process.