Lexmark Card Stock User Manual

Card Stock & Label Guide

Laser Printers

April 2004

www.lexmark.com

Edition: April 2004

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References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in all
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program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any existing intellectual
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This software and any accompanying documentation provided under this agreement are commercial computer software and
documentation developed exclusively at private expense.

2

Contents

Overview.......................................................................................... 5

General Information........................................................................ 6

The Industry ..................... .. ....................................................................... .. .. 6

Print Volumes ................................................................................................ 6

Print Material Testing ..................................................................................... 7

Card Stock..................................................................................... 11

Weight.......................................................................................................... 11

Grain Orientation.......................................................................................... 12

Coatings ....................................................................................................... 13

Offset Powd er s............. .. ............. .. ... ............. .. ............. .. .............. .. .. ............ 14

Labels............................................................................................. 15

Label Characteristics.................. .......................................................... ........ 15

Printing on Labels......................................................................................... 16

Duplexing Paper Labels........................ ...................................... .. ............... 16

Label Components................... ................................................................ .... 18

Label Design Guidelines.................................................... .......................... 20

Printer Specifications................................................................... 27

Lexmark X215.............................................................................................. 27

Lexmark X422.............................................................................................. 30

Lexmark C510.............................................................................................. 33

Lexmark C720.............................................................................................. 35

Lexmark C750.............................................................................................. 37

Lexmark C752.............................................................................................. 42

Lexmark C910.............................................................................................. 47

Contents

3

Lexmark C912.............................................................................................. 49

Lexmark E220.............................................................................................. 51

Lexmark E320, E322.................................................................................... 53

Lexmark E321, E323.................................................................................... 55

Lexmark T420 .............................................................................................. 57

Lexmark T520, T522.................................................................................... 60

Lexmark T620, T622.................................................................................... 66

Lexmark T630, T632, T634.......................................................................... 72

Lexmark W812............................................................................................. 79

Lexmark W820............................................................................................. 80

Optra C......................................................................................................... 82

Optra C710................................................................................................... 82

Optra Color 1200.......................................................................................... 84

Optra E310, E312.............. ................................................................ ........... 85

Optra E, Ep................................................................................................... 86

Optra Es Special Media Printer.................................................................... 87

Optra K 1220................................................................................................ 91

Optra M410, M412 ............................ .. .. ....................................................... 92

Optra N......................................................................................................... 95

Optra plus, 4039, 4029, 4019, WinWriter 600 Printers...................... .. ......... 96

Optra S....................................................................................................... 101

Optra SC 1275 ............................. .. .......................................... .................. 107

Optra T ....................................................................................................... 108

Optra W810................................................................................................ 114

Glossary....................................................................................... 116

Index............................................................................................. 120

Contents

4

Overview

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

This document provides guidelines to help you select appropriate print materials for the foll owing
Lexmark laser printers: all Optra™ models, the 4039 12C, the 4039 10 plus, all 4029 models, all
4019 models, WinWriter™ 600 (4035 5W), and the Lexmark™ C510, C720, C750, C752, C910,
C912, E220, E320, E321, E322, E323, T420, T520, T522, T620, T622, T630, T632, T634, W812,
W820, X215, and X422. The information supplied here supersedes other inf ormation relating to car d
stock and labels included with your printer. Ref er to 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. The glossary on page 116 defines
many industry terms. If you have specific stock or design questions, talk with your print materials
supplier.

Refer to your printer documentation for general printing information and terms. Refer to the printer
registration card, to information on the printer CD or visit our Lexmark Web site at
www.lexmark.com/publications for technical assistance contact numbers.

Always test print materials thoroughly before buying large quantiti es. Doing so will help you avoid
unexpected problems when you begin regular printing.

Overview

5

General Information

The 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. Con verters may work from
rolls with or without the adhesiv e 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 differen t co nverters, and co nverters may work wi th different

manufactur ers, 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 of fer greater expertise and product consi st ency than compani es that c oncentr ate o n
one facet of the process.

Print Volumes

Printing numerous sheets of card stock or labels in a shor t 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. (Look under “Maintenance Procedures” in the
index for specific information about maintaining your printer.)

General Information

6

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 variab les 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 affec t printer rel iability 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 wit h an existing application. In addition, Lexmark has worked with several suppl iers and has
Business Partners in this field. Refer to the printer registration card, to information on the printer CD
or visit our Web site at www.lexmark.com\pub lications for technical assistance contact n u mbers.

Design Factors

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

Basis Weight

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 (see the “Card Stock Weights
Comparison Guide” on page 12). You may want to refer to the metric measurement of grams per
square meter (g/m

Your printer can accept a wi de 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 gr ain short or grain lon g to pro vide fle xibi lity in paper path turns. See the
specifications for each printer for more precise recommendations.

2

) for a more consistent way to compare weights.

Dimensions

All printers hav e print material dimension l imitations . Refer to the printer documentation shipped 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

Print Material Testing

7

Adjustable Tr a y designed f or the Opt ra S, Optra T , and Le xmark T printer famili es prints on a range of
paper sizes including A6 and 3-inch by 5-inch index cards, 3-inch b y 7-inch punch cards and 4-inch
by 6-inch post cards.

Environment

Lexmark printers meet or exc eed 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 stil l in the original wrapper. To condition st ock,
store it in the same environment as the printer for 24 to 48 hours before printing to let the stock
stabilize at the new conditions. You may need to extend this time 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.

If you remove the wrapper from the stock before you’re 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 cu rl is prese nt.

Most label manuf acture rs recommend printing in a temper ature r ange of 18 to 24°C (65 to 75°F) with
relative humidity of 40 to 60%. Lexmark printers are designed to operate in a temperature range of

15.5 to 32°C (60 to 90°F) with relativ e humidity of 8 to 80%. Printing in an en vi ronment out side these
recommendations may cause ja ms, 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 col orations 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 las er printer s that heat the ink to 225°C (437°F).

Print Material Testing

8

Perforations and Die-Cuts

If your f orm has perf or ations , the per f or ation line shoul d stop 1.6 mm (0. 06 in.) from each edge of the
form to av oid separating the f orm in the printer path, resul ting in a jam. The location of t he perfo ration
affects in itial pick strength. P erforations closer to the edge may i n crease 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 strengt h 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 ( als o know n as micro-perfs or data-perfs) provide
greater stability and are pr eferred. These smaller perfor ations do not normally nest or create
excessive paper dust and debris. Make sure paper chaff and dust created during the conv ersion
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, res ult ing i n poor print qua lity. To reduce tenting, use micro-perfs. If the print material i s
lightly snapped as it mov es through the printer, the perf orations should hold without breaking.

Die-cutting is used to create shapes in a label or a card st ock 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 perforat ions 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 di e-cuts or
perforations intersect, ties on the corners of the design provide added stability. Ties may be located
anywhere along perf or ation s or die-cuts . F o r pressure sensi tiv e pro ducts, ties help pr e v ent the l abels
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.

Note: For specific perforation and die-cut guidelines for your printer , see t he app ropriate

topic under “Printer Specifications” on page 27.

Debossing and Embossing

Av oid debossing and embossing materials. Embossi ng leads to nesti ng and double shee t f eeds , 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.

Print Material Testing

9

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 uninter rupted or erro r-free operation of a product. Warranty

service does not include repair of fai lur es caused by:

• modification or attachments

• accidents or misuse

• unsuitable physical or operating environment

• maintenance by anyone other than Lexmark or a Lexmark authorized 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 other than Lexmark supplies (such as ton e r cartridges, inkjet

cartridges, and ribbons)

• use of other than Lexmark product or component

Print Material Testing

10

Card Stoc k

Card stock is a rigid, sti ff material that can have a wide variety of constructions. Orientation of paper
fibers (grai n 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, p reprinting 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.

The following sections describe some of the basic characteristics of card stock. In general, we
recommend a single-ply 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. The basis weight, measured in
pounds (for example, 60 lb Cover stock), is determined by a specified number of sheets for a
particular sheet size. Since the sheet si ze varies from one type of card stock to another, the basis
weights are not always easily comparable. For example, a 100 lb Tag stock may at first glance
appear to be heavier than a 65 lb Cover stock, when in fact the Cover stock is heavier. The area of
the Cover stock is smaller, thus making the weight p er sheet higher.

2

It may be much easier to compare metric weights for card stock (g/m
weights of the two stocks in the previous example , it is immediately evident that the 65 lb Cover
(176 g/m

2

) is heavier than the 100 lb Tag (163 g/m2).

). If you look at the metric

Card Stock

11

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

Card Stock Weights Comparison Guide

Basis Weight (lbs/ream)

Printing

Bond

Metric

Equivalent

2

)

(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.)

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 stocks 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 orientat ion depen ds on the w eight of the s tock and wheth er the printe r f eeds the
stock short-edge first or long-edge first. F or l ighter car d stoc ks , g rain long i s recommended to reduce
potential curl problems. Curl ma y decrease the abilit y of the form to move reliably through the printer.

Grain Orientation

12

Most printers feed paper short-edge first. If your printer supports larger paper sizes, such as 11x17
in. or A3 mm, it may feed some paper sizes long-edge first. Refer to your printer documentation for
more information.

For materials fed short edge first:

GRAIN SHORT IS RECOMMENDED FOR STOCK
HEAVIER THAN

135 g/m

Feed
Direction

Grain
Direction

2

For materials fed long edge first:

GRAIN LONG IS RECOMMENDED FOR STOCK
HEAVIER THAN

135 g/m

2

GRAIN LONG IS RECOMMENDED FOR STOCK
LIGHTER THAN 135 g/m

Feed
Direction

Grain
Direction

GRAIN SHORT IS RECOMMENDED FOR STOCK
LIGHTER THAN

135 g/m2

2

Feed
Direction

Grain
Direction

Feed
Direction

Grain
Direction

See the individual printer specifications in this document for more information about the
recommended grain direction for card stock you use with your printer.

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 slic k surfaces or surfaces that mimic laid fi nishes. 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

Coatings

13

between 100 and 400 Sheffield point s (150 to 25 0 is optimal) . Using media hi gher than 300 Sheffiel d
could result in printing degradation.

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 provi des an int ermediate layer between two sheets of paper, prev enti ng ink tr ansferring from
one sheet to another.

Offset Powders

14

Labels

Labels (also called pr essure sens it ive materials) are multi-ply materials consist ing of a “sandwich” of
various combinations of face sheets (printable stock), adhes ives, and removab le pr otecti ve 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 sto ck can absorb heat, which in turn affect s toner adhesi on and print qualit y an d causes
problems such as delamination.

Note: T o pre vent label s peeling off or delaminating, make sure the release s trength 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 emis sions from the label, up to 160°C (3 20 °F), should be a mi nimal amoun t.
These low boiling point v olatiles 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.

Revie w label designs with a con v erter or vendor who is know ledgeab le about la bels and las er printer
characteristics to ensure you use labels suitable for your application.

Note: Before purchasing large quantit ies of labels, make sure you ex tensively test the

labels with your printer.

Labels

15

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. P artial sheets can also contaminate your printer and
cartridge with adhesive and can void the printer and cartridge service warranties.

Do not feed labels through the printer mor e than once. Doing so may result in adhesive
contamination 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. (Look under “printer maintenance” in the index of your User’s Guide or
publications CD for specific information about maintaining your printer.)

If you print large quantit ies of l abels or other gl ossy print media on a Lexmark C750 or C752, replace
the fuser housing with a web oiler field upgr ade kit (P/N 12G6307 for a 115 V printer, P/N 12G6308
for a 220 V printer).

Duplexing Paper Labels

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

When developing a paper label for duplexing, the converter should ensure that 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 rel ease strength i s suffici ent to withstan d temperat ures 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 possibl e. 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 hel ps pre v ent t he labels from predispens ing 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 that the slits and cuts are not aligned with the ribs in the duplex or
redrive areas of the printer. (“Figure 1” and “Figure 2” on page 17 illustrate the rib locations for the
Optra S and the Optra T, respectively.) This eliminates any contact points betw een the label ad hesive
and the printer, thereby preventing any adhesive contamination in the printer.

Other steps to ensure optimal printing inclu de orienting the label in the tray so that the label end is
fed into the printer first, and usi ng long gr ain paper . Long g rain paper tends to f eed more reli ably than
short grain paper, which tends to curl more easily. As with any industry, product changes and
improvement s are constantl y being de v el oped. Theref or e, if a conv erter de v elops a short grain sheet
for use with duplexed labels, test the sheet to make sure it performs satisfactorily. In fact, we
recommend testing any material with your application and printer before purchasing large quantities.

In order to use the duple x label applicat ion, y ou must install a special fuser wiper. The wax wiper that
is used with the S1855, T612, T614, T520, and T522 is P/N 99A1082. The wax wiper that is used
with the T620 and T622 is P/N 18A1467. The wax wi per that is used with t he T630, T632 and T634 is

Printing on Labels

16

P/N 56P2109. This wiper makes it possible to print on both sides of paper labels specifically
designed for duplexing. In addition, you can u se this 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.

20 mm

21 mm

27 mm

22 mm

15.5 mm

Figure 1. Optra S Rib Locations
(rib width = 2mm)

16 mm

11 mm

15 mm

13 mm

16 mm

17 mm

21.5 mm

26 mm

28 mm

18 mm

12 mm

26 mm

20 mm

17 mm

15 mm

15 mm

4.02 mm

12 mm

Reference

Plate

Reference

Plate

Figure 2. Optra T and Lexmark T Rib Locations
(rib width = 2mm)

Duplexing Paper Labels

17

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 know n 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. (See “Face Sheet (Printable Stock)” on
page 20.) 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 rat her than an auto compensator to separate th e sheets. The f ollowing
table shows which printers use a corner buckler and which use an auto compensator.

Note: If your printer is not listed here, conta ct your Lex mark representative to v erify which

method your printer uses to separate sheets of 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

Lexmark C510, C750, C752, T520, T522, T620,
T622, T630, T632, T634, X215,

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 M.F. (machine finish) or E.F. (English fini sh) papers t hat are calender ed, super calendere d,
or coated on one side. Machine finishes have varying degrees of surface smoothness. The
smoothness is determined by the number of times the paper passes throu gh the rollers (wet or dry)
during manufacturing. An English fini sh is uncoa ted and lo w gloss in appear ance. 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 produces high gloss surfaces that may be slick. Some s upercalendered liners are
difficult for printers 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 sensitiv e constructions use Kraf t liners or b leached Kr aft li ners. Kraft liners ar e made
from sulfate pulp and are M.F. or M.G. (machine glazed). Most machine glazed papers have a high

Label Components

18

gloss appearance. High gloss, glazed surfaces may increase skew and are more difficult for the
printer’s feed mechanism to handle reliably. Some Kraft liners may produce acceptable results;
however, we strongly recommend extensive testing of pressur e 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 fr iction, which can
cause ske w and paper j ams. The f ace material of the liner ne eds to ha v e a melt temper ature t hat 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 ex pose the f ace mat erial to these temper atures an d 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 affec t 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.
The major adhesive-relat ed printing problem is printer and cartridge contamination. The adhesives

are semi-liquid and may contain v olat ile 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 addi tion, 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 fo r mo re information about designing labels for y our printer.

A stripped edge matrix along the outer border of the stock, combined with adhesive that does not
ooze, helps prevent adhesive contaminati on. This design requires a stiffer backing material to
prevent damage when the sheet is aligned on the reference edge. Generally, vinyl and polyester
labels are well suited for this design. Paper and dual web designs may require testing to determine
which backing produces good result s. (See “Label Design Guidelines” on page 20 for more
information on matrices.)

Make sure the release strength is adequate so labels stay attached to t he 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,
perfora tions, or die-cuts. Shear strength should be strong enough to pr event adhesive stringers.
Contact your forms supplier for additional information.

Label Components

19

Face Sheet (Pr i nt able 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 w ant to use can withstand
temperatures of 225°C (437°F) [t emperatures 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 w ater based or solv ent based. A voi d topcoats containing
chemicals that emit haz ardous fumes when heated or exposed t o pressure. Topcoats affec t 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 sect ion for your
specific printer] and pressures up to 25 psi for 100 milliseconds to prevent fuser damage.

Water-bas ed topcoats tend to be more conducti ve than solv ent -based topcoats and are more diffi cult
to fuse. With some water- based topcoats and hea vy liners, the fuse grade may f al l belo w ac ceptable
levels. Solvent-based topcoats tend to be lower in conductivity than water-based topcoats. With
some solvent-based topcoats, fuse grade is within acceptabl e levels when heavier liners are used.

Print quality may degra de when usin g topcoat s on lab els with h ea vier l iners . Using a lighter liner ma y
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 str ipped edge matrix.

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, mak e su re adhesi v e c ontami nation 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 fro m adhesive contamination.

Label Design Guideli nes

20

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. Refer to the following table for stripped
edge matrix guidelines. Measurements may vary ±0.5 mm.

Stripped Edge Matrix Guidelines

Total Weight

Face Type

1

Paper
(Cut Sheet or
Dual Web)

Vinyl 265 - 300 g/m

Polyester
and other face
materials

1

Use a non-oozing adhesive.

2

Must be 1.6 mm (0.0625 in.) in some circumstances. See “Vinyl and Polyester Labels” on page 25.

of Label

140 - 180 g/m

Varies 3.0 mm (0.125 in.)

2

2

Edge Matrix

Removal

1.6 mm (0.0625 in.)

1.6 mm (0.0625 in.)

3.0 mm (0.125 in.)

2.4 mm (0.094 in.)

2.4 mm (0.094 in.)

Location of Strip

215.9 mm (8.5 in.) at leading edge

279.4 mm (11.0 in.) at driver edge

2

2

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

Using cut sheet labels with adhesive applied to the edge of the sheet will contaminate your printer
and your cartridge 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 remo ving th e matrix. If the matrix mus t be re mov ed before printing, round all corners and
make sure adhesive is not exposed.

“Figure 3” on page 22 illustrates a recommended label design for Optra plus printers as well as the
4039, 4029 and 4019 laser printers. The Non-Print Area may vary, depending on the printer model.

Label Design Guideli nes

21

“Figure 4” on page 23 illustrates a recommended label design for Optra S, Optra T, and Lexmark T
laser printers, which uses 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

Driver Edge

11 in.

279.4 mm

0.06 in.

1.6 mm

Perforation End

Liner Edge

waste strip 6.35 mm (0.25 in.)

waste strip

0.25 in.

6.35 mm

0.5 in.

12.7 mm

0.25 in.

6.35 mm

Non-Print Area

0.33 in.

8.38 mm

Top Perforation

0.33 in.

8.38 mm

Non-Print Area

Non-Print Area Non-Print Area

(Not drawn to scale)

Figure 3. Design Guidelines, Vinyl Label for Optra plus, 4039,
4029 and 4019 Printers

Label Design Guideli nes

22

0.094 in.

2.4 mm

Leading Edge

8.5 in.

215.9 mm

Liner Edge

Stripped Edge

0.125 in.
3 mm

Driver Edge

11 in.

279.4 mm

0.06 in.

1.6 mm

Perforation End

Liner Edge

0.25 in.

6.35 mm

0.79 in.

20 mm

0.25 in.

6.35 mm

Non-Print Area

0.33 in.

8.38 mm

Top Perforation

0.33 in.

8.38 mm

Non-Print Area

Non-Print Area Non-Print Area

(Not drawn to scale)

Figure 4. Design Guidelines, Vinyl Label for Optra S, Opt ra T, and
Lexmark T Printers

Cut Sheet Paper Labels

Generally, cut sheet paper labels work well with your printer. Coating or sizing to make the paper
liquid-resistant dec reases 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.

Label Design Guideli nes

23

Dual Web Forms

Constructing dual web f orms in volves 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 withst and the pick
force of the printer.

The two materials must be th in enough for the sheet to lie flat in the paper tr ay . Orient the form in the
tray s o that t he pre ssure sensi tive area feeds into the printer f irst . The form should have no adhesiv e
exposed in the o verlay 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.

See “Figure 5” on page 24 for an illustration of the recommended dual w eb form design. The
Non-Print Area may vary, depending on the printer model.

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

Leading Edge

(8.5 in.)

Liner Edge

Stripped Edge

0.0625 in.

1.6 mm

Reference Edge

(11 in.)

0.0625 in.

1.6 mm

0.25 in.

6.35 mm

Non-Print Area

Pressure Sensitive

Paper

(Not drawn to scale)

Non-Pri n t A rea

0.33 in.

8.38 mm

Overlay

Figure 5. Design Guidelines, Dual Web Form

Label Design Guideli nes

24

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 contaminati on. Thin liners or weak pull strength may lead to labels peeling off the form
inside the printer, which will require printer servicing. See “Figure 3” on page 22 for an illustration of
a vinyl label design for Optra plus printers and “Figure 4” on page 23 for Optra S, Optra T, and
Lexmark T printers.

As illustrated on page 23, 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 hav e liner f ace mel t
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. Look under “maintenance procedures” in the index for specific information about
maintaining your printer. Vinyls may require a topcoat to ensure good toner adhesion.

Polyester label s are less heat sensi tiv e b ut ar e also non-absorbin g. Bac kings f or pol yest er l abels can
be thinner, but requirements for coat ings 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. 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 t he tray into the printer . J amming 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 designi ng a 1 mm (0.04 in.)
non-adhesive border (zone coated) on all four sides.

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

Label Design Guideli nes

25

Due to the unique construction of integrated forms, you may experience stacking problems in the
output bin. Test some forms before purchasing large quantities . Contact your Lexmark marketing
representative if you experience stacking problems with these forms.

Label Design Guideli nes

26

Printer Specifications

Lexmark X215

The Lexmark X215 prints on many labels designed for use
with laser pri n te rs.

Card stock and labels must be fed one sheet at a time
through the manual bypass feeder.

The follo wing table lists the maximum basis weights
supported by the manual bypass feeder.

Lexmark X215: Overview of Card Stock Support

Card Stock

Paper Source

Manual bypass feeder* Up to 163 g/m

* Card stock can only be fed from the manual bypass feeder.

Lexmark X215: Overview of Label Support

Label type

Paper X
Integrated X X
Dual web X X
Vinyl X X

ü - indicates support X - indicates no support

* Labels can only be fed from the manual bypass feeder.

Index Bristol Tag Cover

2

(90 lb) Up to 163 g/m2 (100 lb) —

Print media source

Paper tray Manual bypass feeder*

ü

Printer Specifications

27

For paper and transparency specificati ons, refer to the Lexmark X215 User’s Guide.

Media Specifications

Labels Width: 210 to 216 mm (8.3 to 8.5 in.)

Length: 279 to 297 mm (11 to 11.7 in.)
Weight:

Thickness: Up to 0.25 mm (0.01 in.)
Smoothness: 100 to 400* Sheffield

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

Up to 163 g/m

2

(43 lb bond)

Card Stock Weight:

Up to 163 g/m
Up to 163 g/m

2

Index Bristol (90 lb)

2

Tag (100 lb)

Use only materials recommended for use with laser printers .
To prevent specialty media sheets from stic king togeth er , remo ve each sheet from the output bin as it

is printed.
When printing on labels:

• Set the Paper Type to Labels from the printer driver.

• Use standard size products (either A4 o r Lett e r).

• Do not use label sheets with a slick backing material.

• Do not print within 1 mm (0.040 in.) of the die cut.

• Use full label sheets. Partial sheets may cause labels to peel off during printing, resulting in a

paper jam. Partial sheets will also c ontaminate your printer and your cartridge with adhesive,
and could void your print er and cartridge warranties.

• Use labels that can withstand temperatures of 180°C (356°F) without sealing, excessive

curling, wrinkling, or releasing hazardous emissions.

• V erify that y our label adhesiv e material can toler ate a fus ing temperatu re of 180°C (356°F) f or

0.1 second.

• Use labels that can withstand pressure of 25 pounds per square inch (psi).

• Do not print within 1 mm (0.040 in.) of the edge of the label, of the perforations, or between

die-cuts of the label.

• Do not use label sheets that have adhesive to the edge of the sheet. We recommend zone

coating of the adhesiv e a t least 1 mm (0.040 in.) away from edges. Adhesive material will
contaminate your printer and could void your warranty.

Lexmark X215

28

• If zone coating of the a dhesi v e is n ot possible, a 3 mm (0.125 in.) strip shoul d be remo ved on

the leading and driver edge, and a non-oozing adhesive should be used.

• Remove a 3 mm (0.125 in.) strip from the leading edge to prevent l abels from peeling inside

the printer .

• Portrait orientation is preferred, especially when printing bar codes.

• Do not use labels that have exposed adhesive.

• Do not use labels that are separating from the backing sheet or are wrinkled, bubbled, or

otherwise damaged.

• Do not load a sheet of labels through the machine more than once.

• Load labels into the manual bypass feeder with the recommended print side face up and the

top edge going in first.

When printing on card stock:

• Set the Paper Type to Card Stock from the printer driver.

• Do not use preprinted card stock manufactured with chemicals that may contaminate the

printer. Pre printing introduces semi-liquid and volatile components into the printer.

• Do not use card stock that is creased. It may cause paper jams.

• We recommend the use of grain short card stock.

• Load card stoc k into the manual bypass feeder with the recommended print side face up and

the top edge going in first.

Lexmark X215

29

Lexmark X422: Overview of Card Stock Support

Lexmark X422

The Lexmark X422 prints on many paper labels
designed for use with laser printers.

The printer supports stocks up to 60-199 g/m
(16-53 lb). The standard tray is designed to
handle 100 sheets of paper labels, but its
capacity may be reduced due to the t hickness of
some labels. The multipurpose feeder can feed
up to 10 sheets of card stock.

The following table lists the card stock media
supported.

Card Stock

2

Paper Source

Tray 1 No support
Multipurpos e Feeder*

* Card stock can only be fed from the multipurpose feeder and should always exit to the rear output bin.

Index Bristol Tag Cover

60-199 g/m2 (16-53 lb)

—

Lexmark X422: Overview of Label Support

Print Media Source

Label Type

Paper
Integrated X X X
Dual web XXX
Vinyl XXX

Note: Do not place over 100 label sheets in the standard tray . F eeding labels from print media sources that

are not suppor ted may damage your printe r.

Standard Tray Multipurpose Feeder Optional Trays

ü XX

ü - indicates support X - indicates no support

Lexmark X422

30