Thermal Transfer Tags vs Direct Thermal Tags
The two main differences between these types of tags are whether a ribbon is used and the labels' overall lifespan.
- Thermal Transfer tags require a ribbon to print. They cost more but offer a longer lifespan and are resistant to UV light - ideal for long-term or outdoor use.
- Direct Thermal tags don't use a ribbon, making them cheaper to print, but they're more prone to fading and have a shorter lifespan, especially in sunlight.
Differences between Thermal Transfer and Direct Thermal
| Features | Thermal Transfer | Direct Thermal |
| Uses a ribbon | Yes | No |
| Durability | High | Low |
| Scratch resistant | Yes | No |
| Lifespan | Longer lifespan | Shorter lifespan |
| Suitable for | Outdoor & harsh environments | Indoor environments |
| How it works | Uses ink to produce images | Applies heat to produce images |
| General costs | $0.13c per tag | $0.10c per tag |
PAT Tester Printers
Regarding PAT Tester brands – it's important to understand who offers what before you make a large purchase. Some brands provide both - Direct Thermal and Thermal Transfer, while others offer only one.
Let's break down exactly who uses what.
First, the rank is Seaward PAT testers, and although they utilise various printers (i.e. Primetest Pro Kit, PAC 3760DL Printer Pack and Elite Kit), all of them print solely with Direct Thermal. You need to consider carefully as this will tend to suit warehouses or indoor environments. It's worth mentioning that many people who use Seaward testers still use Direct Thermal tags in outdoor environments.
The ever-popular Metrel brand is a mixed bag, with some units printing Thermal Transfer while others are Direct Thermal. Metrel PAT Testers kits, specifically those using the Zebra TPL and Godex printer, will print Direct Thermal tags. The Zebra ZQ520, used with the Delta Pro Print Pack, is the only Metrel kit that offers Thermal Transfer printing, but this, of course, comes with a higher price tag.
Australian-made Wavecom testers specifically use Thermal Transfer tags for their Portable Appliance Testers, such as the TNP-500 and TNP Prime.
Pros and Cons of Thermal Transfer and Direct Thermal
Thermal Transfer
| Pros | Cons |
| Higher quality and better durability | More expensive option compared to others |
| Longer lifespan | Needs a ribbon to run on a printer (extra cost) |
| Can be used outdoor or indoor | |
| UV resistant | |
| Text, images and barcodes are higher definition |
Direct Thermal
| Pros | Cons |
| Doesn't require a ribbon to print | Lesser quality means it might fade over time |
| More affordable than Thermal Transfer | Can't be used in harsh environments |
Which label is right for you?
Which label you end up choosing will depend mostly on your work requirements and its environment. To simplify the decision-making process, we have created a printer label guide to help you choose the right label for your printer.
If you work in construction or any other kind of harsh environment, then Thermal Transfer will be the one you'll need to use, no questions asked.
However, many businesses find Direct Thermal tags will do the job; they are also acceptable and fine to use (as long as their lifespan is long enough for your environment).
It's worth mentioning that there is a 'sort of' third option, which is the Thermal Transfer XL White Tags. These are unique in that they are highly resistant to direct sunlight and heat - so if you plan to use the label outdoors, it will give the ultimate protection. The main drawback is that they scratch very easily when touched.
Most PAT testers nowadays are moving towards Direct Thermal products, which, at first glance, does seem unusual considering their shorter lifespan, but this is undoubtedly the trend we're seeing from major test and tag brands.
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