Thermal rolls are a crucial part of everyday operations for retail stores, restaurants, pharmacies, supermarkets, courier companies, and e-commerce sellers. Whether you’re printing bills, POS receipts, shipping labels, or barcode stickers, the quality of the thermal roll directly affects print clarity, printing speed, and the overall performance of your machine.

However, many businesses still struggle with choosing the right thermal roll because of the variety of sizes, GSM options, paper coatings, and printer compatibility. Selecting the wrong roll not only reduces printing quality but also causes frequent printer jams, fading receipts, and unnecessary downtime.

1. Know the Type of Thermal Roll You Need

Before you compare size or GSM, start by identifying the correct type of roll based on your business use.

✔ Direct Thermal Rolls (Billing/POS Rolls)

These are used for printing receipts in retail shops, restaurants, small billing machines, and POS terminals. They don’t require ink or ribbons—printing happens through heat.

Common uses:

• Retail billing

• Pharmacy counters

• Petrol pumps

• Parking systems

• Restaurants & cafés

• Supermarkets

✔ Direct Thermal Label Rolls (Shipping/Barcode Labels)

These are adhesive label rolls used for printing shipping labels, barcodes, and inventory tags. Perfect for businesses handling logistics or courier operations.

Common uses:

• E-commerce shipping labels

• Inventory management

• Warehouse barcodes

• Courier packages

• Product tags

Quick Decision Guide:

• For bills and receipts → Choose thermal POS rolls

• For shipping labels → Choose thermal label rolls

2. Choose the Correct Roll Size (Width × Diameter)

Choosing the wrong size is one of the biggest reasons for printing issues. Every thermal printer supports specific roll dimensions.

Popular Thermal Roll Sizes

• 57mm × 40mm – Used in small POS machines, parking systems, portable billing printers

• 80mm × 80mm – Used in large POS printers, supermarkets, retail chains

• 100mm × 150mm – Standard size for shipping labels

• 50mm × 30mm / 75mm × 50mm – Barcode and product labels

How to Find Your Required Size

1. Check current roll packaging

2. Look at your printer manual

3. Measure existing roll width

4. Check printer model compatibility online

Remember:
Width affects print area, while diameter affects how long the roll lasts.

3. Understand GSM (Paper Thickness & Quality)

GSM (grams per square metre) indicates the weight and thickness of the paper. A higher GSM provides stronger, better-quality receipts and labels.

Common GSM Choices

• 48–55 GSM → Standard POS rolls

• 65–70 GSM → Premium quality rolls

• 70+ GSM → Best for durability and dark prints

Why GSM Matters

• Higher GSM produces sharper print

• Thick paper prevents tearing

• Enhances barcode readability

• Ideal for high-volume businesses

For e-commerce labels or long-lasting receipts, 70 GSM is the ideal choice.

4. Prioritize BPA-Free Thermal Rolls

Many low-quality thermal rolls use BPA (Bisphenol A) in their coating, which may not be safe for handling over long durations. BPA-free rolls are now becoming the preferred choice.

Benefits of BPA-Free Paper

• Safer for staff and customers

• Longer-lasting print quality

• Better compatibility with modern printers

• Eco-friendly

If your business focuses on safety and sustainability, always choose BPA-free.

5. Look for High-Sensitivity Paper

Thermal printing works by applying heat to the coated layer of the paper. High-sensitivity thermal rolls offer:

• Faster printing

• Darker and clearer text

• Sharper barcodes

• Less pressure on the print head

• Longer thermal head life

This is especially important for barcode labels and shipping labels, where scan accuracy is critical.

6. Check Printer Compatibility Before Buying

Not all rolls work with all printers. Even small differences in width or core size can impact printing.

Popular Printer Brands That Use Thermal Rolls

• Epson

• TVS

• Rongta

• Zebra

• Brother

• TSC

• HOIN

Always check your printer’s supported roll size and core diameter. Buying incompatible rolls leads to:

• Misalignment during printing

• Frequent jams

• Blank spaces on receipts

• Quick fading

Your supplier should clearly mention compatibility—which Portus Packaging does for all its thermal rolls.

7. Consider Roll Length & Core Size

The length of the roll determines how often you need to replace it. Long rolls reduce downtime and improve workflow during peak hours.

Why Length Matters

• Fewer roll changes

• Better for busy hours

• Reduces staff effort

• Saves time

Core size (the center tube) also matters. Common core sizes are 12mm, 17mm, and 25mm. Many label printers require specific core sizes to fit properly.

8. Choose a Trusted Supplier for Quality Consistency

Even if the specification is correct, the overall quality depends heavily on the supplier. Cheap rolls often come with problems like:

• Faded print

• Low-sensitivity coating

• Shorter length than advertised

• Dusty surface causing printer damage

• Curled or fragile paper

Qualities of a Reliable Supplier

• Accurate roll sizing

• High-sensitivity coating

• Premium paper quality

• BPA-free options

• Strong packaging

• Fast delivery

• Bulk purchase benefits

Portus Packaging ensures consistent quality, accurate roll length, and clear printing for all thermal rolls, making them ideal for daily use.

Conclusion

Choosing the right thermal roll is not just about price—it directly affects the performance of your POS system, shipping label printer, and overall business workflow. High-quality thermal rolls reduce downtime, improve print clarity, and extend the life of your printer’s thermal head.

Whether you’re a retail store, a restaurant, a supermarket, or an e-commerce seller, investing in the right thermal roll ensures smooth daily operations. Portus Packaging offers high-quality thermal rolls in all major sizes, with premium GSM, BPA-free coating, and fast delivery across India—making it easier for your business to stay efficient and productive.