Lexmark C500, C500n, C510, C520, C522 Card Stock & Label Guide

...

Card Stock & Label Guide

Laser Printers

March 2010 www.lexmark.com

Edition notice

March 2010

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Contents

Edition notice......................................................................................2

Overview..............................................................................................7

Introduction.............................................................................................................................................................................7

General information..........................................................................8

Paper and label Industry......................................................................................................................................................8

Print volumes...........................................................................................................................................................................8

Print material testing............................................................................................................................................................8

Design factors..........................................................................................................................................................................9

Pick roller technology........................................................................................................................................................11

Maintenance procedures..................................................................................................................................................13

Troubleshooting..................................................................................................................................................................13

Card stock..........................................................................................15

Weight.....................................................................................................................................................................................15

Grain orientation..................................................................................................................................................................16

Coatings..................................................................................................................................................................................17

Offset powders.....................................................................................................................................................................18

Labels..................................................................................................19

Label characteristics...........................................................................................................................................................19

Printing on labels.................................................................................................................................................................19

Duplexing paper labels.....................................................................................................................................................19

Label components..............................................................................................................................................................21

Label design guidelines....................................................................................................................................................23

Printer specifications......................................................................30

Lexmark C500n.....................................................................................................................................................................30

Lexmark C510.......................................................................................................................................................................31

Lexmark C520, C522, C524...............................................................................................................................................32

Lexmark C530, C532, and C534......................................................................................................................................34

Lexmark C540, C543, C544, and C546dtn...................................................................................................................36

Lexmark C720.......................................................................................................................................................................38

Lexmark C734, C736...........................................................................................................................................................40

Contents

Lexmark C750.......................................................................................................................................................................42

Lexmark C752.......................................................................................................................................................................44

Lexmark C760, C762...........................................................................................................................................................47

Lexmark C770, C772, C780, and C782..........................................................................................................................49

Lexmark C910.......................................................................................................................................................................51

Lexmark C912.......................................................................................................................................................................53

Lexmark C920.......................................................................................................................................................................54

Lexmark C935.......................................................................................................................................................................56

Lexmark E120........................................................................................................................................................................57

Lexmark E220........................................................................................................................................................................58

Lexmark E230, E232, E234(n), E330, and E332n........................................................................................................59

Lexmark E238, E240, E240n, E340, E342n...................................................................................................................60

Lexmark E250, E350, E450n..............................................................................................................................................61

Lexmark E260, E260d, E260dn, E360d, E360dn, E460dn, E460dw, and E462dtn.........................................62

Lexmark E320, E322............................................................................................................................................................63

Lexmark E321, E323............................................................................................................................................................64

Lexmark T420........................................................................................................................................................................66

Lexmark T430........................................................................................................................................................................68

Lexmark T520, T522............................................................................................................................................................70

Lexmark T620, T622............................................................................................................................................................72

Lexmark T630, T632, T634................................................................................................................................................76

Lexmark T640, T642, T644................................................................................................................................................79

Lexmark T650, T652, T654, and T656dne....................................................................................................................81

Lexmark W812......................................................................................................................................................................84

Lexmark W820......................................................................................................................................................................85

Lexmark W840......................................................................................................................................................................86

Lexmark W850......................................................................................................................................................................88

Lexmark X203n and X204n..............................................................................................................................................90

Lexmark X215........................................................................................................................................................................91

Lexmark X264dn, X363dn, X364dn, and X364dw....................................................................................................94

Lexmark X422........................................................................................................................................................................95

Lexmark X463de, X464de, X466dte, and X466dtwe...............................................................................................97

Lexmark X500 and X502n.................................................................................................................................................99

Lexmark X543, X544, and X546dtn.............................................................................................................................100

Lexmark X560.....................................................................................................................................................................102

Lexmark X642e...................................................................................................................................................................103

Lexmark X644e, X646e....................................................................................................................................................106

Contents

Lexmark X651de, X652de, X654de, X656de, and X658de..................................................................................108

Lexmark X734, X736, and X738....................................................................................................................................112

Lexmark X850, X852e, and X854e...............................................................................................................................114

Lexmark X860e, X862e, and X864e.............................................................................................................................116

Lexmark X940, X945.........................................................................................................................................................118

Optra plus, 4039, 4029, 4019, WinWriter 600 printers.........................................................................................119

Optra C..................................................................................................................................................................................123

Optra C710...........................................................................................................................................................................123

Optra Color 1200...............................................................................................................................................................125

Optra E, Ep...........................................................................................................................................................................126

Optra E310, E312...............................................................................................................................................................127

Optra Es special media printer.....................................................................................................................................128

Optra K 1220.......................................................................................................................................................................129

Optra M410, M412............................................................................................................................................................130

Optra N..................................................................................................................................................................................132

Optra S..................................................................................................................................................................................133

Optra SC 1275.....................................................................................................................................................................136

Optra T..................................................................................................................................................................................137

Optra W810.........................................................................................................................................................................140

Glossary............................................................................................142

Index.................................................................................................146

Contents

Overview

Introduction

Lexmark has many years of experience in successful card stock and label testing and education programs with print material vendors and converters.

This document provides guidelines to help you select appropriate print materials for the following Lexmark laser printers.

Model series Models

4019 models All

4029 models All

4039 10 plus All

4039 12C All

C series C500, C510, C520, C522, C524, C530, C532, C534, C540, C546dtn, C543, C544, C720, C734, C736,

C750, C752, C760, C762, C770, C772, C780, C782, C910, C912, C920, C935

E series E120, E220, E230, E232, E234(n), E238, E240, E250, E260, E320, E321, E322, E323, E330, E332n, E340,

E342n, E350, E360, E450, E460, E462dtn

OptraTM models

T series T420, T430, T520, T522, T620, T622, T630, T632, T634, T640, T642, T644, T650, T652, T654, T656dne

W series W812, W820, W840, W850

WinWriterTM 600

X series X203, X204, X215, X264, X363, X364, X422, X463, X464, X466, X500, X502, X543, X544, X546dtn,

The information supplied here supersedes other information relating to card stock and labels included with your printer. See other printer documentation for detailed information about the paper, envelopes, and transparencies suitable for your printer.

In addition to printer-specific media recommendations, this document also explains design factors you should consider when purchasing all types of print materials. For definitions of industry terms, see “Glossary” on page 142. If you have specific stock or design questions, talk with your print materials supplier.

See your printer documentation for general printing information and terms. For technical assistance contact numbers, see the printer registration card, information on the printer CD, or visit the Lexmark Web site at

http://support.lexmark.com.

Note: Always test print materials thoroughly before buying large quantities. Doing so will help you avoid unexpected

problems when you begin regular printing.

All

4035 5W

X560(n), X642e, X644e, X646e, X651, X652, X654, X656, X658, X734, X736, X738, X850, X852e, X854e, X860e, X862e, X864e, X940, X945

Overview

General information

Paper and label Industry

The paper and label industry includes several different types of businesses: manufacturers, converters, and distributors.

Manufacturers produce the base stock. If the base is for labels, manufacturers may ship it on large rolls or in a cut-sheet form.

Converters take the base stock and convert it into cut-sheet products. Converters may work from rolls with or without the adhesive applied, or they may take a base stock and convert it to meet their customers' specifications.

The conversion process includes, but is not limited to, cutting the stock to size, perforating the stock, die-cutting, and applying inks and topcoats. Converters work with their customers to convert the base material into a cut-sheet product designed for use in laser printers.

Distributors generally are the direct link to the customer.

Distributors may work with different converters, and converters may work with different manufacturers, as their needs and prices change. Most businesses follow accepted industry conventions, but specifications, standards, formulations, and processes may vary with time or with different companies.

Note: Labels or papers that performed satisfactorily in the past may suddenly create printing problems because of a change in material or process.

Some large businesses perform all three functions, from manufacturing to distribution. These companies may offer greater expertise and product consistency than companies that concentrate on one facet of the process.

Print volumes

Printing numerous sheets of card stock or labels in a short period of time can create printing problems. Exclusive printing of labels, for example, may result in more frequent service calls. Proper printer maintenance helps alleviate these problems. For information about maintaining your printer, see “Maintenance procedures” on page 13.

Print material testing

Choosing print materials can seem complex. Unfortunately, it is not possible to write a simple "cookbook" explaining how to select print materials, because there are too many variables you need to address for each specific application.

Be aware that critical factors at the vendor—such as the physical characteristics of the base stock and the manufacturing processes—may change over time.

Print materials can significantly affect printer reliability and downtime. Using materials from converters or vendors who are unfamiliar with laser printing may result in unsatisfactory print quality or other printing problems.

Note: Once you have a successful design, test the print material before placing a large order to avoid costly mistakes.

Your print materials supplier should be able to help develop your application or solve a problem you have with an existing application. In addition, Lexmark has worked with several suppliers and has business partners in this field. For technical assistance contact numbers, see the printer registration card, information on the printer CD, or visit the Lexmark Web site at support.lexmark.com.

General information

Design factors

Print materials all have measurable characteristics that you need to consider when selecting or designing forms for your particular application.

Basis weight

Basis weight is a term used to describe the weight in pounds of 500 sheets of paper (one ream). However, the weight is determined based on the standard size of the paper, which may not be the purchased size. For example, the standard size of 20-lb bond paper is 17 x 22 inches, and a ream of 17 x 22-inch 20-lb bond paper weighs 20 pounds. If the 17 x 22-inch 20-lb bond paper was cut, creating four reams of 8.5 x 11-inch paper, each ream would be labeled 20-lb bond paper but would only weigh five pounds.

If the same paper weighed 24 pounds, it would be called 24-lb bond. The 24-lb bond paper is thicker, heavier, and more dense than the 20-lb bond. Thicker paper means less paper can be placed in a tray, and paper that is heavier and more dense may cause paper jams or feed reliability problems in some printers. Check the supported paper weights table located in the printer documentation to verify that the paper basis weight being used is acceptable.

Not all basis weights are related to the same standard sheet size: for example, 70-lb material can be lighter than 40-lb material if it is based on larger base size paper. The metric measurement of grams per square meter (g/m consistent way to compare weights and has b een standardized by the International Organization for St andardization (ISO). For more information, locate your printer in the “Printer specifications” chapter.

Your printer can accept a wide range of stock weights, but materials either too light or too heavy can cause printing problems. Heavy and/or thicker materials may not heat quickly enough in the fuser, resulting in poor print quality. They may also feed less reliably or skew due to their weight or rigidity. Conversely, lighter materials can wrinkle and jam in the printer due to low beam strength (stiffness).

Depending on the orientation of the stock as it feeds through the printer, you may need to request that heavier materials be cut grain short or grain long to provide flexibility in paper path turns. For more precise recommendations, locate your printer in the “Printer specifications” chapter.

) is a more

Dimensions

All printers have print material dimension limitations. See the printer documentation that came with your printer for details. You can sometimes redesign forms to overcome these limitations. For example, if you use forms that are shorter than the minimum length supported by your printer, you may be able to link two forms together when printing multiple forms. An optional Universally Adjustable Tray designed for the Optra S, Optra T, and Lexmark T printer families prints on a range of paper sizes including A6 and 3 x 5-inch index cards, 3 x 7-inch punch cards, and 4 x 6-inch postcards.

Environment

Lexmark printers meet or exceed all industry emission regulations and standards. Continuous printing on some papers or other media may create fumes that are not a problem with occasional printing. Make sure your printer is located in a well-ventilated area.

Temperature and humidity can have a major impact on printing. Even small changes (such as from day to night) can greatly affect feed reliability if the print material is just within the range of acceptability.

We recommend that you condition stock while it is still in the original wrapper. To condition stock, store it in the same environment as the printer for 24–48 hours before printing to let the stock stabilize at the new conditions. You may need to extend this time by several days if the storage or transportation environment is very different from the printer environment. Thick stock may also require a longer conditioning period because of the mass of the material.

General information

If you remove the wrapper from the stock before you are ready to load it in the printer, the stock may develop uneven moisture content that can cause curl. Prior to loading your stock, we recommend that curl not exceed 3 mm (0.125 in.). Lighter materials, such as paper labels and some integrated forms, are more likely to have printing problems if curl is present.

Most label manufacturers recommend printing in a temperature range of 18–24°C (65–75°F) with relative humidity of 40–60%. Lexmark printers are designed to operate in a temperature range of 15.5–32°C (60 to 90°F) with relative humidity of 8 to 80%. Printing in an environment outs ide these recommenda tions may cause jams, feeding problems, reduced print quality, and predispensing (peeling) labels.

Inks (preprinted stock)

Preprinted stock introduces semi-liquid and volatile components to the high temperatures and pressure used in the laser printing process. Preprinted inks and colorations must withstand a fuser temperature up to 225°C (437°F) and pressure up to 25 psi without contaminating the printer or creating hazardous fumes.

Thermography inks are not recommended. Thermography inks have a waxy feel and the printed image appears raised above the surface of the print material. These inks can melt and damage the fuser assembly.

Preprinted inks must also be abrasion resistant to reduce ink dust and ink contamination in the printer. If you are printing over a preprinted area, the ink must be receptive to toner to ensure adequate fusing.

All preprinted inks must be thoroughly dry before using printed materials. However, we do not recommend using offset powders or other foreign materials to speed drying. Check with your converter, or the manufacturer or vendor of the ink you plan to use, to determine if the ink is compatible with laser printers that heat the ink to 225°C (437°F).

Perforations and die-cuts

If your form has perforations, the perforation line should stop 1.6 mm (0.06 in.) from each edge of the form to avoid separating the form in the printer path, resulting in a jam. The location of the perforation affects initial pick strength. Perforations closer to the edge may increase the number of jams. For pressure-sensitive materials such as labels, minimize the number of perforations that go through the backing material, or liner, since these can also affect the strength of the form.

Perforations should be ironed so the print material lies flat, reducing nesting of forms. Edges should be smooth and clean with no roll-over. Laser-perfs (also known as micro-perfs or data-perfs) provide greater stability and are preferred. These smaller perforations do not normally nest or create excessive paper dust and debris. Make sure paper chaff and dust created during the conversion process are removed before packaging.

If perforations tent, or crease at the perforation line, the perfs may break, causing a paper jam. Tenting may increase skew, cause double-sheet feeding, or smear the toner on the print material before fusing, resulting in poor print quality. To reduce tenting, use micro-perfs. If the print material is lightly snapped as it moves through the printer, the perforations should hold without breaking.

Die-cutting is used to create shapes in a label or a card stock design. When designing labels, round all corners to prevent delamination of the labels, and avoid cuts through the liner (anvil cuts). Back splits and pop-out windows are also not recommended.

If perforations or die-cuts are part of the design of the print material, ties are recommended. These small uncut areas (approximately 1.6 mm or 0.06 in.) help stabilize the form and prevent tearing at perforations and die-cuts during printing.

For areas with die-cuts or perforations that create a small end product, or where die-cuts or perforations intersect, ties on the corners of the design provide added stability. Ties may be located anywhere along perforations or die- cuts. For pressure-sensitive products, ties help prevent the labels from peeling off the liner while in the printer. Ties cannot, however, be used to compensate for inadequate release strength of the adhesive in label designs.

General information

For specific perforation and die-cut guidelines for your printer, locate your printer in the “Printer specifications” chapter.

Debossing and embossing

Avoid debossing and embossing materials. Embossing leads to nesting and double-sheet feeds, and the fusing process significantly reduces the height of the raised image. Printing too close to embossments results in poor print quality and poor fuse grade.

Metallics

We do not recommend using metallics in forms, whether in inks or other materials, due to their conductivity and their ability to bleed charge. This can interfere with toner transfer and cause poor print quality.

Basic form design

When designing forms, include a non-print area of 8.38 mm (0.33 in.) at the top and bottom of the form and 6.35 mm (0.25 in.) on both sides of the form.

In general, portrait orientation is the preferred layout, especially if you are printing bar codes. If your forms require landscape orientation, be aware that variations in paper path speed may produce spacing variations when printing bar codes.

Note: We do not warrant uninterrupted or error-free operation of a product. Warranty service does not include repair of failures caused by:

• modification or attachments

• accidents or misuse

• unsuitable physical or operating environment

• maintenance by any unauthorized (non-Lexmark) servicer

• operation of a product beyond the limit of its duty cycle

• failure to have installed a maintenance kit as specified (if applicable)

• use of printing media outside of Lexmark specifications

• use of non-Lexmark supplies (such as toner cartridges and/or inkjet cartridges)

• use of non-Lexmark product or component

Pick roller technology

Some printers have an auto compensator which feeds paper more reliably than the corner buckler system used by earlier printer models. The auto compensator has two rollers that touch the media. Avoid placing deep perforations in these areas since the media may nest, causing multiple sheets to feed. Perforations that could cause nesting and tenting should fall outside the pick roller area on the leading edge of the media. (This is different from the 0.50-inch space we recommend leaving at the top of the form for printers with a corner buckler system.) You may want to use micro-perfs to avoid nesting problems. For more information, see “Perforations and die-cuts” on page 10.

General information

For the following printers, make sure perforations fall outside the 0.3–0.79-inch area on the leading edge of the media: Optra S, Optra T, T520, T522, T620, T622, T630, T632, T634, T640, T642, T644, T650, T652, T654, T656dne, X203, X204, X264, X363, X364, X463, X464, X466, X543, X544, X546dtn, X560n, X642e, X644e, X646e, X651, X652, X654, X656, X658, X734, X736, X738.

General information

For the following printers, make sure perforations fall outside the 0.31–1.05-inch area on the leading edge of the media: C520, C522, C524, C530, C532, C534, C540, C543, C544, C546dtn, C734, C736, C750, C752, C760, C762, C770, C772, C780, C782.

Maintenance procedures

If the print quality begins to degrade when printing sheets of vinyl labels, we suggest you follow the three cleaning steps below:

1 Print five sheets of paper.

2 Wait approximately five seconds.

3 Print five more sheets of paper.

To maintain printer feeding reliability, repeat this cleaning process every time you replace the black cartridge, more often with some media. Failure to follow maintenance procedures for your printer could cause jamming, poor print quality, feeding problems, and fuser problems.

Troubleshooting

The following table provides solutions for some common card stock and label problems. For more troubleshooting information, see your printer documentation.

General information

Solutions to printing problems

Problem Solution

Print on heavy stock is blurred or out of focus.

Make sure the Paper Type setting is appropriate for your print material. (Card stock in excess

of 203 g/m

[54-lb bond] may not produce acceptable print results.)

Print five sheets of paper, wait approximately five seconds, and then print five more sheets of paper to remove any toner that may have accumulated.

Toner rubs off the page. Make sure the Paper Type setting is appropriate for your print material.

Use a lighter weight stock. (The material being used should be lighter than 300 g/m2.)

Print five sheets of paper, wait approximately five seconds, and then print five more sheets of paper to remove any toner that may have accumulated.

Printing shows voids. Change the Paper Type to Plain Paper.

Print five sheets of paper, wait approximately five seconds, and then print five more sheets of paper to remove any toner that may have accumulated.

General information

Card stock

Card stock is a rigid, stiff material that can have a wide variety of constructions. Orientation of paper fibers (grain direction), moisture content, thickness, texture, and other properties can significantly impact printing, as can preprinting, perforation, creasing, and other features common to forms. For example, preprinting introduces semi-liquid, volatile components that must withstand the high temperatures used in laser printing. Perforation and creasing may cause nesting, or interlocking, which can cause paper jams and double-sheet feeds.

T he fo llow in g s ec t io ns de s cr ib e s o me of th e ba si c c h ar ac te r is ti cs of c ar d s toc k. In gen er al , w e re co mm en d a s in g le -p ly construction of 100% chemically-pulped wood with a vellum finish. Before purchasing large quantities of card stock, make sure you test samples of the print material in your printer.

Weight

The weight of card stock plays a significant role in the print quality and feed reliability of the stock. Confusion often arises when specifying the basis weight of a stock; for more information, see “Basis weight” on page 9. The basis weight is a term used to describe the weight in pounds of 500 sheets of paper (one ream). Since the sheet size varies from one type of stock to another, the basis weights are not always easily comparable. For example, an office supply store has 8.5 x 11-size cover stock (80 lb Bristol) and 8.5 x 11-size card stock (90 lb Index) side by side on the shelf. Both papers are manufactured by the same company, and a basis weight comparison indicates the card stock (90 lb Index) is heavier than the cover stock (80 lb Bristol). In this example, the cover stock (80 lb Bristol) is actually heavier than the card stock (90 lb Index).

The reason the cover stock is heavier is because before the two types of paper were cut into 8.5 x 11-size pages, the card stock was a larger sheet size than the sheet size of the cover stock. When the papers were cut during the manufacturing process into 8.5 x 11-size pages, more reams (500 sheets) of paper were received from the card stock sheets than from the cover stock sheets. This makes the weight of the cover stock heavier than the weight of the card stock.

It is easier to compare the cover stock metric weight (g/m the metric weights of the two stocks in the previous example, it is immediately evident that 80 lb Bristol cover stock

(176 g/m

Not all printers are able to print on cover stock. This is because cover stock is usually thicker and not able to make the turns in the printer paper path. This causes paper jams and sometimes causes the paper to feed incorrectly. Also, when using a laser printer, toner is pulled onto the paper through an electrical charge. If the paper is too thick, then there may not be enough voltage to pull the toner onto the paper properly, resulting in poor print quality.

To determine if your printer is able to print on cover stock, locate your printer in the “Printer specifications” chapter and review the supported paper type informat ion. You can also view the supported paper types in the documentation that came with your printer.

Use the following table to compare the weights of various types of card stock.

) is heavier than 90 lb Index card stock (163 g/m2).

) against card stock metric weight (g/m2). If you look at

Card stock

Card stock weights comparison

Basis weight (lbs/ream)

Bond

Metric

equivalent

(g/m

)

75 20 50 — — — 50

90 24 60 — — — —

105 28 70 — — — —

108 29 — 40 — — —

118 31 80 — — — —

120 32 — — — 67 74

131 35 90 — — — —

135 36 — 50 — — —

148 39 100 — — — —

163 43 — 60 — 90 100

176 47 120 65 — — —

199 53 — — 110 110 —

203 54 — — — — 125

431.8 x

558.8 mm

(17 x 22 in.)

Offset

635 x

965.2 mm

(25 x 38 in.)

Cover

508 x

660.4 mm

(20 x 26 in.)

Printing Bristol

571.5 x 889 mm (22.5 x 35 in.)

Index Bristol

647.7 x 774.7 mm (25.5 x 30.5 in.)

Tag

609.6 x

914.4 mm

(24 x 36 in.)

Card stock weights may vary ± 5%.

Depending on the printer, material thicker than 0.30 mm (0.012 in.) may present feed reliability problems, and material thicker than 0.17 mm (0.007 in.) may reduce print quality. Contact your supplier to determine the weight of any card stock you currently use.

See the individual printer specifications in this document for more information about the card stock weights your printer supports.

Grain orientation

Grain refers to the alignment of the paper fibers in a sheet of paper. Grain is either grain short, running the width of the paper, or grain long, running the length of the paper.

The orientation of the grain contributes to the rigidity of card stock and affects feed reliability. The recommended grain orientation depends on the weight of the stock and whether the printer feeds the stock short edge first or long edge first. For lighter card stocks, grain long is recommended to reduce potential curl problems. Curl may decrease the ability of the form to move reliably through the printer.

Most printers feed paper short edge first. If your printer supports larger paper sizes, such as 11 x 17 in. or A3, it may feed some paper sizes long edge first. See your printer documentation for more information.

Card stock

For materials fed short edge first:

Grain short is recommended for stock heavier than 135 g/m

Feed directio

Grain direction

For materials fed long edge first:

Grain long is recommended for stock heavier than 135 g/m

Grain long is recommended for stock lighter than 135 g/m

Feed directio

Grain direction

Grain short is recommended for stock lighter than 135 g/m

Feed direction

Grain direction

See the individual printer specifications in “Printer specifications” on page 30 for more information about the recommended grain direction for card stock you use with your printer.

Feed direction

Grain direction

Coatings

Surface texture and coatings on card stock significantly affect toner adhesion (fuse grade), print quality, and feed reliability. We recommend a vellum finish for the best printing performance. We do not recommend glossy coatings and slick surfaces or surfaces that mimic laid finishes (glossy paper, not glossy card stock, is acceptable for some printers). Paper smoothness also affects print quality. If the paper is too rough, the toner does not fuse to the paper properly; if the paper is too smooth, it can affect feed reliability. We recommend smoothness to be between 100 and 400 Sheffield points (150–250 is optimal). Using media higher than 300 Sheffield could result in printing degradation.

Card stock

Offset powders

We do not recommend using offset powders or other foreign materials to speed drying. Offset powders are used by print shops to prevent printed pages from sticking together. Powder is usually sprayed on the printed page right before it reaches the stacker on the offset printing press. This powder provides an intermediate layer between two sheets of paper, preventing ink from transferring from one sheet to another.

Card stock

Labels

Labels (also called pressure-sensitive materials) are multi-ply materials consisting of a "sandwich" of various combinations of face sheets (printable stock), adhesives, and removable protective backings (liners). The multiple layers can result in thick, difficult-to-handle materials.

Labels are among the most difficult print materials for any printer to reliably feed and print. The heat, pressure, and paper paths required by laser printers create a particularly difficult environment for printing labels. Temperatures near 225°C (437°F) [temperatures vary between printers; check the section for your specific printer] and pressures to 25 psi can be necessary for the fusing process. Heavy label stock can absorb heat, which in turn affects toner adhesion and print quality and causes problems such as delamination.

Note: To prevent labels peeling off or delaminating, make sure the release strength of the labels you use is sufficient to withstand the temperature and pressure extremes generated during printing.

Label characteristics

The materials used to construct labels have a wide range of properties that can affect printing. In addition to volatile components in adhesive, volatiles are also in some label materials. We recommend that volatile emissions from the label, up to 160°C (320°F), should be a minimal amount. These low boiling point volatiles can produce emissions when they are heated in the fuser and they can potentially produce vapors which can cause damage to the printer. Preprinted inks can also cause printer contamination, and may be present on one or both sides of the label sheet.

Observing recommended label design guidelines can minimize contamination as well as prevent other critical problems, such as labels peeling off and causing jams in the printer, or the label or adhesive melting if the sheet stops in the fuser during a paper jam.

Review label designs with a converter or vendor who is knowledgeable about labels and laser printer characteristics to ensure you use labels suitable for your application.

Note: Before purchasing large quantities of labels, make sure you extensively test the labels with your printer.

Printing on labels

Use full label sheets only. Partial sheets (with areas exposed by missing labels) can cause labels to peel off during printing, resulting in a paper jam. Partial sheets can also contaminate your printer and cartridge with adhesive and can void the printer and cartridge service warranties.

Do not feed labels through th e printe r more than once. Doing so may result i n adhesive co ntamination to the cartridge and other components.

Depending on your printer model and the number of labels you print, printing labels may require special printer maintenance. For specific maintenance information, see the documentation that came with your printer.

For more information about printing labels, locate your printer in the “Printer specifications” chapter.

Duplexing paper labels

Due to the special construction of labels, they are not typically duplexed. However, if certain design, construction, and usage guidelines are followed, you can print on both sides of the label sheet successfully.

Labels

When developing a paper label for duplexing, the converter should ensure the label design protects against contamination or buildup. Contamination adversely affects paper feeding and causes paper jams in the printer.

We recommend labels used for duplexing have a non-adhesive border around the label area. In addition, make sure the release strength is sufficient to withstand temperatures of 225°C (437 °F) and pressures to 25 psi. This is particularly important with a duplex application since the label is subjected to these extremes twice. Use label ties whenever possible. These small uncut areas (approximately 1.6 mm or 0.06 in.) help stabilize the label sheet and prevent tearing at perforations and die-cuts during printing. In addition, using ties helps prevent the labels from predispensing in the printer.

The slits and cuts in the labels expose the adhesives to the printer. For best results when duplexing labels, position the label sheet so the slits and cuts are not aligned with the ribs in the duplex or redrive areas of the printer. This eliminates any contact points between the label adhesive and the printer, thereby preventing any adhesive contamination in the printer. The following graphics show the rib locations for the Optra S, Optra T, and Lexmark T, respectively.

Optra S rib locations (rib width = 2 mm):

20 mm

21 mm

27 mm

22 mm

Optra T and Lexmark T rib locations (rib width = 2 mm):

16 mm

11 mm

15 mm

13 mm

16 mm

17 mm

15.5 mm

21.5 mm

26 mm

28 mm

18 mm

12 mm

26 mm

20 mm

17 mm

15 mm

Reference Plate

12 mm

4.02 mm

Reference Plate

Labels

Other steps to ensure optimal printing include orienting the label in the tray so the label end is fed into the printer first, and using grain long paper. Grain long paper tends to feed more reliably than grain short paper, which tends to curl more easily. As with any industry, product changes and improvements are constantly being developed. Therefore, if a converter develops a grain short sheet for use with duplexed labels, test the sheet to make sure it performs satisfactorily.

Note: We recommend testing any material with your application and printer before purchasing large quantities.

To use the duplex label application, you must install a special fuser wiper.

Printer Fuser wiper part number

S1855, T612, T614, T520, and T522 99A1082

T620 and T622 18A1467

T630, T632 and T634 56P2109

T64x, X644e, and X646e 40X2666

T65x and X65x 40X2666

The wiper makes it possible to print on both sides of paper labels specifically designed for duplexing. In addition, you can use the wiper to simplex paper labels and duplex paper in the same printer. When ordering a new cartridge, be sure to order the cartridge that includes the correct fuser wiper.

Label components

Labels are composed of three basic parts: the liner, the adhesive, and the face sheet. Labels may also have topcoats that affect printing. Choosing appropriate materials for each of these label components will help ensure reliable printing.

Liners

The liner, also known as the carrier or backing, is the material onto which the label is attached. The liner carries the label through the printer and directly affects feed reliability. Liner weights and construction vary based on the printable face stock used (for more information, see “Face sheet (printable stock)” on page 23). Tissue-backed, plain bond, or bond-like, porous, lay-flat liners are preferred. Liners constructed for use in high speed laser printers (50 or more pages per minute) may not produce acceptable results.

A liner should bend easily and snap back to its original flat state when released. If the form remains bent, it may cause paper jams or damage to the edge of the sheet, particularly in earlier printer models using a corner buckler rather than an auto compensator to separate the sheets. The following table shows which printers use a corner buckler and which use an auto compensator.

Note: If your printer is not listed here, contact your Lexmark representative to verify which method your printer uses to separate sheets of labels.

Labels

Printers using a corner buckler Printers using an auto compensator

• 4019, 4029, 4039, 4049

• Lexmark E220, E320, E321, E322, E323, T420, W820,

X422

• Optra 12L, 12R, Lxi, Lx, Rx

• Optra R+, Rt+, Lx+, Lxi+

• Optra C, Optra Color 1200, Optra N

• Optra M410, M412, W810

• C910, C912, C920

• Lexmark E230, E232, E234(n), E330, E332n, E260, E360,

E460, C510, C520, C522, C524, C530, C532, C534, C540, C734, C736, C750, C752, C760, C762, C770, C772, C780, C782, C935, T520, T522, T620, T622, T630, T632, T634, T640, T642, T644, T650, T652, T654, X203, X204, X215, X264, X363, X364, X463, X464, X466, X540, X642e, X644e, X646e, X651, X652, X654, X656, X658, X734, X736, X738, W840

• Optra S 1250, S 1650, S 2450

• Optra S 1255, S 1625, S 1855, S 2455

• Optra Se 3455

• Optra T610(n), T612(n), T614(n), T616(n)

Some liner materials used in pressure-sensitive constructions are called label papers. Label papers are either MF (machine finish) or EF (English finish) papers that are calendered, supercalendered, or coated on one side. An MF has varying degrees of surface smoothness. The smoothness is determined by the number of times the paper passes through the rollers (wet or dry) during manufacturing. An EF is uncoated and low gloss in appearance. Label papers may also be used as the face sheet for pressure-sensitive paper products, such as the materials used in dual web forms construction.

Supercalendering p ro du c es hi gh g lo ss su r fa ce s t h at ma y b e s li ck . S om e s up er c al en de re d l in er s ar e d if fi c ul t f or pr i nt er s to pick and feed reliably. We do not recommend using supercalendered liners designed for high-speed laser printers (50 or more pages per minute).

Some pressure-sensitive constructions use Kraft liners or bleached Kraft liners. Kraft liners are made from sulfate pulp and are MF or MG (machine glazed). Most MG papers have a high gloss appearance. High gloss, glazed surfaces may increase skew and are more difficult for the printer feed mechanism to handle reliably. Some Kraft liners may produce acceptable results; however, we strongly recommend extensive testing of pressure-sensitive constructions using Kraft liners.

Tissue-backed or plain bond liners reduce toner contamination inside the printer and improve feed performance. Slick, non-porous liners are harder to feed and increase toner buildup in the fuser and on the backup roll. Rough backings, on the other hand, can increase paper path friction, which can cause skew and paper jams. The face material of the liner needs to have a melt temperature that can also withstand the fuser temperatures of nearly 225°C (437°F). Since there is a stripped area of a maximum of 3 mm, this can expose the face material to these temperatures and could cause melting or contamination in the fuser.

Excessive paper dust or chaff associated with the liner may affect print quality. If a liner material produces excessive paper dust or chaff during the conversion process, some of this debris may be packaged with the material and end up in the printer. Liner materials that produce excessive paper dust or chaff as they feed through the printer may also affect print quality.

Your forms supplier can provide additional information on liners.

Adhesives

There are three basic types of label adhesives: removable, permanent, and semi-permanent (cold temp). All types, with proper design, can be used with your printer. Acrylic-based adhesives are generally preferred for cut-sheet label printers.

Labels

The major adhesive-related printing problem is printer and cartridge contamination. The adhesives are semi-liquid and may contain volatile components. If the sheet jams in the fuser, the adhesive can melt, thereby contaminating parts of the printer or releasing fumes. To avoid exposing adhesive to the paper path guides, drive rollers, charge roller, photoconductor drum, transfer roller, and detack fingers, use full label sheets.

Zone coating means placing the adhesive only where needed. Paper labels and integrated forms typically use zone coating. In addition, a non-adhesive border of 1 mm (0.04 in.) around the outside edge of the label sheet generates good results. Check with your adhesive manufacturer or forms supplier for more information about designing labels for your printer.

A stripped edg e matrix along the outer border of the stock, combined with adhesive that does not ooze, helps prevent adhesive contamination. This design requires a stiffer backing material to prevent damage when the sheet is aligned on the reference edge. Generally, vinyl and polyest er labels are well-suited for this design. Paper and dual web designs may require testing to determine which backing produces good results. (For more information on matrices, see “Label design guidelines” on page 23.)

Make sure the release strength is adequate so labels stay attached to the liner and do not peel off in the printer. Adhesives must be able to withstand pressures to 25 psi and fuser temperatures of 225°C (437°F) without delaminating, creating hazardous fumes, or oozing around edges of labels, perforations, or die-cuts. Shear strength should be strong enough to prevent adhesive stringers. Contact your forms supplier for additional information.

Face sheet (printable stock)

Paper, vinyl, and polyester are the most common materials used for printable stock. Your forms supplier can provide information on whether the printable stock you want to use can withstand temperatures of 225°C (437°F) [temperatures vary between printers; check the section for your specific printer] and pressures to 25 psi. Carefully test the stock to ensure it functions satisfactorily with your printer.

Topcoats

Topcoats for non-paper labels may be either water based or solvent based. Avoid topcoats containing chemicals that emit hazardous fumes when heated or exposed to pressure. Topcoats affect the print quality, feed reliability, and adhesion of toner to the face sheet. Topcoats must be able to withstand temperatures up to 225°C (437°F) [temperatures vary between printers; check the section for your specific printer] and pressures up to 25 psi for 100 milliseconds to prevent fuser damage.

Water-based topcoats tend to be more conductive than solvent-based topcoats and are more difficult to fuse. With some water-based topcoats and heavy liners, the fuse grade may fall below acceptable levels. Solven t-based topcoat s tend to be lower in conductivity than water-based topcoats. With some solvent-based topcoats, fuse grade is within acceptable levels when heavier liners are used.

Print quality may degrade when using topcoats on labels with heavier liners. Using a lighter liner may reduce the appearance of splatter. Test forms carefully with your printer to be sure the topcoat used performs acceptably for your application.

Label design guidelines

Labels with a stripped edge matrix have the area around the outer edge of the cut sheet removed. Labels with a total strip matrix have the unneeded portion of the die-cut stock around the labels (including a portion between the labels)

removed to make it easier to peel the labels from the backing.

Butt cut labels are cut flush to one another, with no extra area between them. Avoid using butt cut labels without a stripped edge matrix.

Labels

Die-cut labels are cut with a non-print area between each label. For best results, do not print within 2.3 mm (0.090 in.) of the edge of the label, of the perforations, or of the die-cuts of the label.

If you are using a butt cut or die-cut label, make sure adhesive contamination does not occur. Labels use varying levels and types of adhesive, as well as a variety of liner materials and face stocks. Adhesive can ooze with all label stocks. Make sure die-cuts are free of adhesive stringers. Zone coating or pattern adhesive with a 1-mm (0.04-in.) or larger non-adhesive border provides the greatest protection from adhesive contamination.

If zone coating is not used, we recommend a stripped edge matrix. The stripped edge matrix varies with the type of face stock, liner, and adhesive materials. See the following table for stripped edge matrix guidelines. Measurements may vary ±0.5 mm.

Stripped edge matrix guidelines

Face type Total weight of label Edge matrix removal Location of strip

Paper1 (Cut Sheet or Dual Web)

Vinyl

140–180 g/m

265–300 g/m

1.6 mm (0.0625 in.)

3.0 mm (0.125 in.)

2.4 mm (0.094 in.)

215.9 mm (8.5 in.) at leading edge

279.4 mm (11.0 in.) at driver edge

215.9 mm (8.5 in.) at leading edge

279.4 mm (11.0 in.) at driver edge

Polyester and other face materials

Use a non-oozing adhesive.

Edge matrix removal must be 1.6 mm (0.0625 in.) in some circumstances. For more information, see “Vinyl and polyester

Varies 3.0 mm (0.125 in.)

2.4 mm (0.094 in.)

215.9 mm (8.5 in.) at leading edge

279.4 mm (11.0 in.) at driver edge

labels” on page 28.

Using cut sheet labels with adhesive applied t o the edge o f the sheet will contaminate your printer and your c artridge and could void your printer and cartridge warranties.

When using pressure-sensitive materials without zone coating, choose butt cut labels without any stringers and with a stripped edge matrix. If a total strip matrix is in the design for the final product, print before removing the matrix. If the matrix must be removed before printing, round all corners and make sure adhesive is not exposed.

The following diagram shows a recommended label design for Optra plus printers, 4039, 4029, and 4019, as well as the T610, T520, T620, and T630 laser printers.

Note: The non-print area may vary, depending on the printer model.

Labels

Liner edge

Stripped edge

0.125 in. 3 mm

Driver edge

11 in.

279.4 mm

Leading Edge

8.5 in.

215.9 mm

0.094 in.

2.4 mm

Waste strip 0.25 in (6.35 mm)

Waste strip

0.5 in.

12.7 mm

Non-print area

0.33 in.

8.38 mm

Top perforation

0.06 in.

1.6 mm

Perforation end

Liner edge

0.25 in.

6.35 mm

Non-print area Non-print area

(Not drawn to scale)

0.25 in.

6.35 mm

0.33 in.

8.38 mm

Non-print area

Labels

The following diagram shows a recommended label design for the T640 and T650 laser printers.

Labels

The following diagram shows a recommended label design for Optra S, Optra T, and Lexmark T laser printers, which use a different paper picking mechanism.

Leading Edge

8.5 in.

215.9 mm

0.094 in.

2.4 mm

Liner edge

Stripped edge

0.125 in. 3 mm

0.79 in. 20 mm

Driver edge

11 in.

279.4 mm

Non-print area

0.33 in.

8.38 mm

Top perforation

0.33 in.

0.06 in.

1.6 mm

Perforation end

Liner edge

0.25 in.

6.35 mm

Non-print area Non-print area

(Not drawn to scale)

0.25 in.

6.35 mm

8.38 mm

Non-print area

Cut sheet paper labels

Generally, cut sheet paper labels work well with your printer. Coating or sizing to make the paper liquid-resistant decreases toner adhesion and increases the risk of toner contaminating the fuser. At a minimum, paper labels should be equivalent in weight and rigidity to a 20-lb xerographic bond paper.

Dual web forms

Constructing dual web forms involves joining together rolls of two different materials (usually pressure-sensitive paper and bond paper) and then converting to a cut sheet product. This construction requires a stripped edge matrix. The liner must be rigid enough to withstand the pick force of the printer.

Labels

The two materials must be thin enough for the sheet to lie flat in the paper tray. Orient the form in the tray so that the pressure-sensitive area feeds into the printer first. The form should have no adhesive exposed in the overlay area or anywhere along the front or back of the form. We recommend designing a non-adhesive strip with a minimum width of 1 mm (0.04 in.) along the edges of the overlay.

To help prevent material from slipping in the fuser, we recommend knurling, which roughens up the exposed silicon area at the glue joint.

The face sheet of a dual web form is usually a paper pressure-sensitive product; therefore, the guidelines for paper labels are applicable to dual web forms.

The following diagram shows the recommended dual web form design. The non-print area may vary, depending on the printer model.

Leading edge

(8.5 in.)

0.0625 in.

1.6 mm

Liner edge

Stripped edge

Non-print area

0.0625 in.

1.6 mm

Reference edge

(11 in.)

Non-print area

Pressure-sensitive

Paper

0.25 in.

6.35 mm

(Not drawn to scale)

0.33 in.

8.38 mm

Overlay

Vinyl and polyester labels

Vinyl labels work well within specified design parameters. Vinyls are heat-sensitive, so the liners need to be thick enough to absorb excess heat and prevent melting. A total strip matrix may cause adhesive contamination. Thin liners or weak pull strength may lead to labels peeling off the form inside the printer, which will require printer servicing. For more information on recommended label designs, see “Label design guidelines” on page 23.

Labels

For Optra S, Optra T, and Lexmark T printers, a leading and trailing edge stripped area is recommended to be a maximum of 3 mm. This area is recommended to prevent adhesive being close to the edge, which can contaminate your printer. Certain materials used in label construction, which have liner face melt temperatures lower than the fuser temperature, may require the leading and trailing edge stripped areas to be 1.6 mm maximum due to feeding problems. It is preferred that the liner face be constructed with material that can withstand our fuser temperatures, which eliminates the need for changing the stripped areas from 3 mm to 1.6 mm. If a 1.6-mm stripped area is used, it is very important that the 1.6-mm tolerance be held tightly. With a stripped area of less than 1.6 mm, it is highly possible that adhesive contamination will occur.

Vinyls are non-absorbing, which leads to toner build-up in the fuser that requires special maintenance. See the documentation that came with your printer for specific information about maintaining your printer. Vinyls may require a topcoat to ensure good toner adhesion.

Polyester labels are less heat-sensitive but are also non-absorbing. Backings for polyester labels can be thinner, but requirements for coatings and cleaning are similar to vinyl labels.

It is recommended that when you run vinyl labels, you install a special oil fuser cleaner, P/N 99A0725 or 40X2665. When you order a new cartridge, be sure to order the cartridge that will include the correct fuser cleaner.

Integrated forms

To create integrated forms, the converter uses hot melt adhesives to apply the label adhesive and liner to a base material (generally paper). Oil bleed, recognizable by a discolored face sheet, can be a problem with these forms. Oil may also migrate from the top of the liner to the back surface of the liner while it is on the roll, before the conversion process takes place. The forms created from this material may then be slick, and the pick mechanism of your printer may be unable to successfully move all the sheets from the tray into the printer. Jamming and misfeeds increase when oil is present on the back of the liner.

The adhesive on these forms is commonly patterned on two or four sides (that is, the forms have a non-adhesive border on either two or four edges). We recommend designing a 1-mm (0.04-in.) non-adhesive border (zone coated) on all four edges.

When printing on integrated forms with a grain long base material, orient the form in the tray so the paper portion of the form feeds into the printer first. Orient the pressure-sensitive portion of the form toward the portrait left edge. For integrated forms with a grain short base material, orient the form in the tray so the pressure-sensitive portion feeds into the printer first.

Due to th e unique construct ion of integrated forms, you may expe rience stacking prob lems in the output bin. Contact your Lexmark marketing representative if you experience stacking problems with these forms.

Note: Test some forms before purchasing large quantities.

Labels

Printer specifications

Lexmark C500n

Limit label printing to occasional use of paper office labels designed for laser printers. The Lexmark C500n does not support vinyl or polyester labels.

The Lexmark C500n supports 90–210-g/m Tray 2.

Tray 1 supports approximately 120 sheets of card stock and Tray 2 supports up to 250 sheets of card stock. The following table lists the maximum weights supported.

(24–55-lb) stock. Card stock and labels are supported from Tray 1 and

Overview of card stock and label support

(Grain short is preferred for papers over 135 g/m

Paper source

Tray 1 (standard tray)

Tray 2 (optional tray)

Index Bristol Tag Cover Paper

90–210 g/m

* Vinyl labels are not supported.

Media specifications

Labels

Card Stock

Width: 76.2–216 mm (3–8.5 in.)

Length: 123.8–355.6 mm (4.88–14 in.)

Weight:

180 g/m

(48 lb)

Thickness: 0.13–0.20 mm (0.005–0.008 in.)

Smoothness: 100–400 Sheffield*

* 150–250 Sheffield is optimal. Using media higher than 300 Sheffield could result in printing degradation.

Weight:

163-g/m

(90-lb) Index Bristol

(100-lb) Tag

Up to 210-g/m

Card stock

90–210 g/m

(78-lb) Cover

) Labels*

90–210 g/m

180 g/m

Printer specifications

+ 116 hidden pages

Lexmark C500, C500n, C510, C520, C522 Card Stock & Label Guide

Specifications and Main Features

Frequently Asked Questions

User Manual