Linerless labels offer plenty of space for important information and product labelling and do not require any paper or other liner materials. As a result, linerless technologies have become increasingly popular in recent years, particularly in relation to environmental protection. But is this just a current hype or is there more potential behind it? This is the question we want to explore with the experts from Zebra.

Jakob Nieweg: Welcome to today’s interview. We’re going to be discussing the developments and opportunities in linerless label technology, a topic that is currently attracting a lot of attention in the industry. Joining me are Zebra experts Phil Reynolds, Head of Regional Product Management –Scanning, Print and Supplies, Kevin Davies, Product Manager Mobile Print, William Heyes, Product Manager Supplies and Alex Holdsworth, Product Manager Industrial Print. Great to have you all here. Phil, would you like to give us an overview?

Phil Reynolds: Thank you, Jakob. linerless labelling – label printing without a liner – has gained significance in recent years. Many people’s perception of linerless is that it is all about sustainability benefits, but that is just half of the story. Through Zebra’s development of our proposition customers have found that it offers so much more. Zebra’s ZeroLiner solution is about improving the workflow and realising cost and other resource efficiencies and productivity gains, as well as improving worker safety alongside sustainability benefits. Eliminating backing liner material to reduce waste is just one of many positives. However, we need to make it clear that linerless printing does come with its own set of challenges and we advise that customers test the solution to make sure they understand the solution fully, and that the technology is suitable for their application. Having said that when we speak with customers who have adopted linerless printing the benefits far outweigh the challenges.

Jakob Nieweg: Interesting. Kevin, could you tell us more about the technical challenges that might arise with this technology?

Kevin Davies: Sure, Jakob. One of the biggest challenges is adhesive ooze from poor quality media. This is where the adhesive on the back of the label seeps out and contaminates the printer mechanism. This could lead to printer jams or poorly printed labels, which is especially problematic. Zebra has taken the approach to develop its own ZeroLiner media solution which, when paired with its linerless printers, ensures that adhesive ooze is a thing of the past for our customers. However, Zebra still recommends that regular cleaning of the printer is essential with any linerless label solution. While traditional labels require cleaning every three to five rolls, we recommend cleaning after each roll of linerless labels. Most customers understand this need when we explain it to them, but in practice cleaning is often forgotten or only done sporadically.

Phil Reynolds: Exactly, Kevin! It’s an additional requirement, but if it’s followed, the system runs smoothly. And the cleaning itself is actually a quick and easy process that ensures efficient long-term operation. The extra effort involved in the cleaning cycle is easily outweighed by the benefits of not having to remove the liner, which is costly and time consuming with traditional labels.

Jakob Nieweg: That sounds like an adjustment in workflow. William, what about the compatibility of linerless labels with printers? Is that another factor customers should consider?

William Heyes: Absolutely! Compatibility between the printer and the media used plays a major role. Our teams have conducted numerous tests on our ZeroLiner branded media to ensure optimum compatibility with our range of linerless printers. But not all linerless media are the same. Some customers run into difficulties when they use third-party media. That’s why we always recommend using Zebra ZeroLiner media with Zebra linerless printers.

We also offer printhead and platen roller protection programs for those customers using Zebra linerless printer and ZeroLiner supplies and reach a certain print volume. Our partners receive replacement printheads and platen rollers at no extra cost by signing up.

Jakob Nieweg: It sounds like Zebra has a pretty complete linerless story in terms of hardware, supplies and programs. What does the future of the portfolio look like?

Alex Holdsworth: It is very interesting you mention this, as we have just launched the ZT411 Linerless, our first ever linerless industrial printer. This gives us the benefits of linerless printing in an industrial form factor that we have never had before. With the launch of the industrial printer, we also launched dedicated ZeroLiner media, so there are dedicated linerless supplies that will work in these printers as well.

Jakob Nieweg: This is great, Alex, but what about customers who already have a ZT411 and want to try linerless?

Alex Holdsworth: There is more good news, we also launched a field upgrade kit, which means that customers or resellers are able to retrofit existing ZT411s with linerless printing in the field.

Jakob Nieweg: There will be thousands of ZT411 in the field, so this provides a massive opportunity for resellers across EMEA who want to migrate customers over to linerless technology! How does this printer compare to the ZD621 desktop linerless printer we sell today?

Alex Holdsworth: With the ZT411 Linerless, customers are now able to print up to 10,000 linerless labels per day, significantly higher than the maximum label volume of a ZD621 Linerless. If you need a printer that prints higher volumes, position the ZT411. If you want a more compact form factor at a lower price point, then the ZD621 is the way to go.

Kevin Davies: Don’t forget we have linerless on the entire mobile portfolio except the ZQ220 plus, and linerless isn’t a new technology on mobile.

Jakob Nieweg: Got it, thank you. Let’s move on to the market landscape: How do you see the future of this technology? Is there enough demand?

Phil Reynolds: Absolutely! According to our data, the market for linerless labels is growing at around 5 % annually. Internally at Zebra, we are seeing a growth rate higher than that, showing that many end users find the technology really interesting. I receive inquiries about linerless applications on an almost daily basis.

Kevin Davies: This is also my experience. I regularly talk to customers who are interested. Just last week, I had nine conversations with end-users, and only two of them hadn’t considered linerless before. The topic has been on the radar for several years, and with the introduction of devices like the ZT411 to the industry, interest continues to grow.

Jakob Nieweg: That certainly sounds like a clear trend. What advantages do linerless labels offer compared to conventional labels?

Phil Reynolds: Well, the most obvious benefit is the reduced material usage as there’s no liner to discard. This brings two distinct additional benefits that may not be obvious. The first is related to the fact that there is more usable material on a roll of linerless material. This means there are more labels per roll and therefore fewer rolls to transport and store for the same print volume. This should reduce transport and storage costs.

The second benefit is that the absence of a liner means there is no need to collect and dispose of the liner, eliminating both inefficient processes and waste from the customer’s operations. 

Jakob Nieweg: Do you see linerless as a universal solution or are there specific use cases where it’s more suitable?

William Heyes: Linerless is certainly not the solution for every application. There are certain applications where the technology is particularly well suited – such as in the hospitality, retail or logistics sectors, where continuous label printing is required. But there are also scenarios where traditional labels remain the better choice. It’s best to thoroughly test the technology beforehand to ensure that it meets the specific requirements.

Jakob Nieweg: Thanks for these insights. What would you advise a customer who’s interested in using linerless labels? How should they proceed?

Phil Reynolds: My advice would be to order a test printer and try out the linerless technology in a demo. If it’s to replace an existing system, our Printer Trade Up programme is a good option.

Kevin Davies: : I recently spoke with a customer in Germany who wanted to test two printer models – one with and one without liner material – in parallel. Especially for new applications, this comparison is valuable to determine which version better meets the requirements.

William Heyes: And I would definitely recommend using Zebra ZeroLiner media. We often see customers running into issues with third-party media, and using Zebra media allows them to take advantage of our protection programmes such as Print Head Protection and Platen Protection once they reach a certain volume.

Jakob Nieweg: Understood! Is there anything else you’d like to add?

Phil Reynolds: Now is the time to start engaging with linerless technologies. In the past, linerless printer may have been seen as a hype – perhaps customers questioned the ability of print media to be truly sustainable. However, what Zebra has come to appreciate are the many tangible business benefits that linerless offers. Customers who invest in Zebra’s linerless solutions and follow the recommended maintenance programme are realising the benefits.

Kevin Davies: That’s right! Customers are increasingly choosing sustainable solutions and we’re seeing a clear demand for technologies that combine productivity with environmental friendliness. So, I think linerless is here to stay.

Jakob Nieweg: Thank you all for your time and the fascinating insights. I think our audience has gained a solid understanding of the challenges and opportunities in linerless technology.

Next time you call, ask your sales representative about the innovative linerless technologies from Zebra!