AllTroubleshoot

Why Is My Shipping Label Not Printing? Fixes That Work

Most shipping label print problems have one of three causes: the labels are loaded the wrong way, the printer hasn't learned the label size, or the computer is sending the wrong paper size. Start with the symptom you see below. Each fix takes a minute or two. The steps come from Rollo's and Zebra's own support pages, two of the most common thermal label printers. Most other 4x6 thermal printers work the same way.

Step-by-step

1
Blank labels? Flip the roll
Rollo says the most common reason for blank labels is labels loaded upside down. The printable side must face the print head; on a Rollo, the peel-off side faces up as it comes out. Also check you are using direct thermal labels. These printers use heat, not ink, and other label types stay blank.
2
Labels skipping or feeding nonstop? Recalibrate
The printer needs to learn the gap between labels, especially after you change label brand or size. On a Rollo: unplug the USB cable, then hold the top button until you hear one beep. It feeds labels back and forth, then stops at the tear-off point with a green light. On a Zebra ZD421: hold PAUSE and CANCEL together for two seconds to run SmartCal.
3
Label cut off or tiny? Fix the paper size
Set the paper size to 4 x 6 inches (100 x 150 mm) in the printer settings. On Windows that is under Printer Preferences, then Advanced on a Rollo. On a Mac, choose 100 x 150 mm or 4 x 6 in the print window. Apps such as Adobe Reader can override the driver, so check Page Setup there too.
4
Shrunk or off-center? Print at 100%
In the print window, pick 'Actual size' or 100% scale, not 'Fit to page'. Shrinking a label can make the barcode too small to scan. If it is still shifted, adjust the label margins in the printer settings.
5
Nothing prints at all? Check the basics
Make sure the right printer is selected (the PDF viewer may default to another printer), the cable or Wi-Fi is connected, and the printer shows a ready light. Then print a test page: on a Rollo, hold the top button until you hear two beeps.

Good to know

•Zebra: you don't need to recalibrate when you load more labels of the same type, brand and size. Recalibrate when you switch.
•Rollo: keep several labels loaded while it learns the label size.
•A label printed on a regular printer must be on white paper. USPS recommends a laser printer or an inkjet at 600 dpi so the barcode scans.
•Lost a label because of a jam? You can usually reprint it from the site where you bought it. For USPS Click-N-Ship, that is only until 11:59 PM Central Time on the ship date.

Quick fixes by symptom

What you see	Most likely cause	Fix
Blank labels come out	Roll loaded upside down, or not direct thermal labels	Flip the roll; use direct thermal labels
Prints part of the label	Paper size set to letter or a different size	Set 4 x 6 in (100 x 150 mm) in the printer and the app
Skips labels or feeds many	Printer hasn't learned the label gap	Recalibrate (Rollo: one beep; Zebra: SmartCal)
Label is tiny or shifted	'Fit to page' scaling or margins	Print at 100% / Actual size; adjust margins
Nothing happens	Wrong printer selected or not connected	Select the label printer; print a test page

Zebra printer not printing the full label

Run SmartCal first: with labels loaded and the cover closed, hold PAUSE and CANCEL for two seconds. The printer feeds a few labels and adjusts its sensors. If it still cuts the label short, check that the label size set on the printer or in your app matches the roll. Zebra's manual calibration (in Advanced mode) is the next step if SmartCal can't read your labels.

Rollo printer not printing the full label

Rollo's fix is to re-learn the label: unplug USB, hold the top button until one beep, wait for the green light, and plug back in. Then confirm the paper size is 100 x 150 mm (4 x 6) in Printer Preferences or the print window. If the print is still clipped at an edge, adjust the label margins in the Rollo settings.

Printing a ShippingLabel.co label

Labels made on ShippingLabel.co download as a PDF. Open it, choose your label printer, set the paper to 4 x 6 (or letter for letter-size labels), and print at 100%. If the preview looks right but the paper comes out blank or cut off, use the printer fixes above.

Frequently asked questions

Why is my thermal label printer printing blank labels?

Most often the labels are loaded upside down, so the heat-sensitive side faces away from the print head. Flip the roll. Also make sure the labels are direct thermal; other labels won't change color.

Why is my label printer not printing the full label?

The paper size in your app or driver doesn't match the roll, or the printer hasn't learned the label size. Set 4 x 6 in (100 x 150 mm), then recalibrate the printer.

How do I reset or calibrate my thermal printer?

On a Rollo, unplug USB and hold the top button until one beep. On a Zebra ZD421, hold PAUSE and CANCEL for two seconds (SmartCal). Other brands have a similar button sequence in their manual.

Why does my label print on half a page?

The print window is set to letter-size paper while a 4 x 6 label is loaded, or the reverse. Choose the paper size that matches what's in the printer, and print at 100%.

My label prints faded. What can I do?

Raise the print darkness or density in the printer settings, and use fresh direct thermal labels. Old labels, or labels kept somewhere hot, may print light.