Lexmark Card Stock & Label Guide User Guide

Card Stock & Label Guide

Laser Printers

October 2012 www.lexmark.com

Edition notice

October 2012

The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL,
INC., PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED
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program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any existing intellectual
property right may be used instead. Evaluation and verification of operation in conjunction with other products, programs, or services,
except those expressly designated by the manufacturer, are the user’s responsibility.

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Contents 3

Contents

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

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

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

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

Paper and label industry............................................................................................................................8

Printing volumes........................................................................................................................................8

Testing print material................................................................................................................................8

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

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

Maintenance procedures........................................................................................................................14

Troubleshooting......................................................................................................................................14

Card stock..................................................................................................16

Weight.....................................................................................................................................................16

Grain orientation.....................................................................................................................................17

Coatings...................................................................................................................................................18

Offset powders........................................................................................................................................19

Labels.........................................................................................................20

Label characteristics................................................................................................................................20

Printing on labels.....................................................................................................................................20

Duplexing paper labels............................................................................................................................20

Primary rib pattern design guidelines for reference edge alignment.....................................................22

Label components...................................................................................................................................23

Label design guidelines...........................................................................................................................25

Printer specifications..................................................................................32

Lexmark C500n........................................................................................................................................32

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

Lexmark C520, C522, and C524...............................................................................................................34

Lexmark C530, C532, and C534...............................................................................................................36

Lexmark C540, C543, C544, and C546dtn...............................................................................................38

Lexmark C720..........................................................................................................................................40

Contents 4

Lexmark C734 and C736..........................................................................................................................42

Lexmark C746 and C748..........................................................................................................................44

Lexmark C750..........................................................................................................................................46

Lexmark C752..........................................................................................................................................48

Lexmark C760 and C762..........................................................................................................................51

Lexmark C770, C772, C780, and C782.....................................................................................................53

Lexmark C792e, C792de, C792dte, and C792dhe...................................................................................54

Lexmark C910..........................................................................................................................................56

Lexmark C912..........................................................................................................................................58

Lexmark C920..........................................................................................................................................59

Lexmark C925..........................................................................................................................................61

Lexmark C935..........................................................................................................................................62

Lexmark C950..........................................................................................................................................64

Lexmark CS310n, CS310dn, CS410n, CS410dn, and CS510de.................................................................65

Lexmark CX310n, CX310dn, CX410e, CX410de, CX410dte, CX510de, CX510dhe, and CX510dthe.........67

Lexmark E120..........................................................................................................................................69

Lexmark E220..........................................................................................................................................70

Lexmark E230, E232, E234(n), E330, and E332n.....................................................................................71

Lexmark E238, E240, E240n, E340, and E342n........................................................................................72

Lexmark E250, E350, and E450n.............................................................................................................73

Lexmark E260, E260d, E260dn, E360d, E360dn, E460dn, E460dw, and E462dtn...................................74

Lexmark E320, E322................................................................................................................................75

Lexmark E321, E323................................................................................................................................76

Lexmark MS310d, MS310dn, MS410d, MS410dn, MS510dn, MS610dn, and MS610de........................77

Lexmark MS710 and MS711....................................................................................................................79

Lexmark MS810, MS811, and MS812......................................................................................................82

Lexmark MX310dn, MX410de, MX510de, MX511de, MX511dhe, MX610de, MX611de, and

MX611dhe...........................................................................................................................................84

Lexmark MX710, MX711, MX810, MX811, and MX812..........................................................................86

Lexmark T420..........................................................................................................................................89

Lexmark T430..........................................................................................................................................91

Lexmark T520, T522................................................................................................................................93

Lexmark T620, T622................................................................................................................................96

Lexmark T630, T632, T634......................................................................................................................99

Lexmark T640, T642, T644....................................................................................................................102

Lexmark T650, T652, T654, and T656dne..............................................................................................104

Lexmark W812.......................................................................................................................................107

Contents 5

Lexmark W820.......................................................................................................................................108

Lexmark W840.......................................................................................................................................109

Lexmark W850.......................................................................................................................................111

Lexmark X203n and X204n....................................................................................................................113

Lexmark X215........................................................................................................................................114

Lexmark X264dn, X363dn, X364dn, and X364dw..................................................................................116

Lexmark X422........................................................................................................................................118

Lexmark X463de, X464de, X466dte, and X466dtwe.............................................................................119

Lexmark X500 and X502n......................................................................................................................121

Lexmark X543, X544, and X546dtn........................................................................................................122

Lexmark X548........................................................................................................................................124

Lexmark X560........................................................................................................................................125

Lexmark X642e......................................................................................................................................127

Lexmark X644e, X646e..........................................................................................................................129

Lexmark X651de, X652de, X654de, X656de, and X658de.....................................................................132

Lexmark X734, X736, and X738.............................................................................................................135

Lexmark X746 and X748........................................................................................................................137

Lexmark X782........................................................................................................................................139

Lexmark X792de, X792dte, X792dtfe, X792dtpe, X792dtme, and X792dtse........................................141

Lexmark X850, X852e, and X854e.........................................................................................................143

Lexmark X860e, X862e, and X864e.......................................................................................................145

Lexmark X925........................................................................................................................................147

Lexmark X940 and X945........................................................................................................................149

Lexmark X950........................................................................................................................................150

Optra plus, 4039, 4029, 4019, WinWriter 600 printers.........................................................................151

Optra C..................................................................................................................................................155

Optra C710............................................................................................................................................155

Optra Color 1200...................................................................................................................................157

Optra E, Ep.............................................................................................................................................158

Optra E310, E312...................................................................................................................................159

Optra Es special media printer..............................................................................................................160

Optra K 1220.........................................................................................................................................161

Optra M410, M412................................................................................................................................162

Optra N..................................................................................................................................................164

Optra S...................................................................................................................................................165

Optra SC 1275........................................................................................................................................168

Optra T..................................................................................................................................................169

Contents 6

Optra W810...........................................................................................................................................172

Glossary...................................................................................................174

Index........................................................................................................178

Overview 7

Overview

Introduction

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

Series Printer models

4019 All

4029 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,

C746, C748, C750, C752, C760, C762, C770, C772, C780, C782, C792e, C792de, C792dte, C792dhe,
C910, C912, C920, C925, C935, C950, CS310n, CS310dn, CS410n, CS410dn, CS510de, CX310n,
CX310dn, CX410e, CX410de, CX410dte, CX510de, CX510dhe, CX510dthe

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

M series MS310d, MS310dn, MS410d, MS410dn, MS510dn, MS610dn, MS610de, MS710, MS711, MS810,

MS811, MS812, MX310dn, MX410de, MX510de, MX610de, MX611de, MX611dhe, MX710, MX711,
MX810, MX811, MX812

TM

Optra

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

W series W812, W820, W840, W850

TM

WinWriter

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 to consider when
purchasing all types of print materials. For definitions of industry terms, see “Glossary” on page 174. If you have specific
stock or design questions, then contact your print materials supplier.

600

All

4035 5W

X548, X560(n), X642e, X644e, X646e, X651, X652, X654, X656, X658, X734, X736, X738, X746, X748,
X782, X792de, X792dte, X792dtfe, X792dtpe, X792dtme, X792dtse, X850, X852e, X854e, X860e,
X862e, X864e, X925, X940, X945, X950

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.

General information 8

General information

Paper and label industry

The paper and label industry includes manufacturers, converters, and distributors.

• Manufacturers produce the base stock. If the base is for labels, then 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. They may also 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 are generally the direct link to the customer.

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

As a result, labels or paper that worked well 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.

Printing volumes

Printing numerous sheets of card stock or labels in a short period of time can create printing problems. Continuous
printing on labels, for example, may result in more frequent service calls. The glue on the labels can be squeezed out
by the rollers in the printer and contaminate other printer parts. Most labels and card stock have cuts or perforations
that can be abrasive if not ironed or flattened.

Special media, in general, have rough coatings and are thicker.

Proper printer maintenance can help you avoid these problems. For information about maintaining your printer, see
“Maintenance procedures” on page 14.

Testing print material

Consider the following factors when choosing print materials:

• Physical characteristics of the base stock and the manufacturing processes, which are dependent on the vendor,

may change over time.

• The quality of print materials can also 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.

Once a design is finalized, test the print material before placing a large order to avoid costly mistakes.

General information 9

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

http://support.lexmark.com.

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

2

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 been standardized by the International Organization for Standardization
(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.

General information 10

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.

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 outside these recommendations 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
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.

perfs (also known as micro‑perfs or data‑perfs) provide greater stability and are preferred.

‑

cutting is used to create shapes in a label or a card stock design. When designing labels, round all corners to prevent

Die

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.

General information 11

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.

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 12

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 13

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, C792e, C792de, C792dte, C792dhe, CS310n, CS310dn, CS410n, CS410dn, CS510de, CX310n, CX310dn,
CX410e, CX410de, CX410dte, CX510de, CX510dhe, CX510dthe, X792de, X792dte, X792dtfe, X792dtpe, X792dtme, and
X792dtse.

General information 14

For the following printers, make sure perforations fall outside the 0.12–0.91‑inch area on the leading edge of the media:
MS710, MS711, MS810, MS811, MS812, MX710, MX711, MX810, MX811, and MX812.

Pick Roller Location

0.12 in.

0.91 in.

0.56 in.

1.08 in.

2.76 in.

3.28 in.

Direction of Feed

Maintenance procedures

Note: These procedures apply only to mono laser printers.

If print quality begins to degrade when printing on vinyl labels, then do the following:

1 Print on five sheets of paper.

2 Wait approximately five seconds.

3 Print on five more sheets of paper.

To maintain printer feeding reliability, repeat this cleaning process every time you replace the toner cartridge.

Note: Failure to follow maintenance procedures for your printer could cause jams, poor print quality, feeding
problems, and fuser problems.

Troubleshooting

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

General information 15

Problem Solution

Print on heavy stock is
blurred or out of focus.

Make sure the Paper Type setting is correct for your print material.

Note: Card stock in excess of 203 g/m

2

(54‑lb bond) may not produce acceptable print

results.

Print on five sheets of paper, wait for 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 correct for your print material.

2

Use material that is lighter than 300 g/m

.

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

Card stock 16

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.

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 significantly affects the print quality and feed reliability of the stock. Specify the correct basis
weight of a stock. For more information, see “Basis weight” on page 9.

Basis weight is the weight in pounds of one ream, or 500 sheets, of paper. Since the sheet size varies from one type of
stock to another, 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 case, however, the cover stock (80 lb Bristol) is actually heavier than the card stock (90 lb
Index).

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.

2

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

2

(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 supports cover stock, see the section for your printer in the "Printer specifications" chapter
and review the supported paper type information. 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 the

Card stock 17

Card stock weights comparison

Basis weight (lbs/ream)

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.)

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.

For materials fed short edge first:

n

n

Card stock 18

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

Feed
direction

2

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

Feed
directio

Grain
direction

2

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

Feed
direction

2

2

Grain
direction

See the individual printer specifications in “Printer specifications” on page 32 for more information about the
recommended grain direction for card stock you use with your printer.

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 o r surfaces that mimic laid finishes (glo ssy paper, not glossy card sto ck, is acceptable for some printer s).
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 19

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.

Labels 20

Labels

Labels , or pressure‑sensitive materials, are multi‑ply materials that contain various combinations of face sheets
(printable stock), adhesives, and removable protective backings (liners). These layers can result in thick materials that
are difficult to handle.

Labels are among the most difficult print materials for any printer to reliably feed and print. Factors such as heat,
pressure, and paper path could make printing on labels quite challenging. For example, 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 from peeling off or delaminating, make sure the release strength of the labels 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. Volatile components
are in the label materials and in the adhesive itself. We recommend that volatile emissions from the label, up to 160°C
(320°F), should be a minimal amount. The volatile components, which have low boiling point, produce emissions when
heated in the fuser and could emit vapors that can damage the printer.

Preprinted inks can also cause printer contamination, and may be present on one or both sides of the label sheet.

Follow the recommended label design guidelines to prevent labels from peeling off, which could cause jams. The label
or adhesive could also melt if the sheet is jammed in the fuser.

Review label designs with a converter or a vendor who has extensive knowledge about labels and laser printers to
ensure that you are using the proper type of labels.

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

Printing on labels

Print on full label sheets only. Sheets with missing labels could peel off during printing and result in a paper jam. Partial
sheets can also leave adhesive marks on the printer and cartridge, which could void the printer and cartridge service
warranties.

Do not feed labels through the printer more than once. Doing so may contaminate the cartridge and other components
with adhesive.

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

For more information about printing on labels, see the section for your printer in the “Printer specifications” chapter.

Duplexing paper labels

Labels are not typically duplexed because of their special construction. However, printing on both sides of the label
sheet may be possible if certain design, construction, and usage guidelines are followed.

Labels 21

When developing a paper label for duplexing, the converter should make sure that the label is designed to protect
against contamination or buildup. Contamination could result in paper feed problems and paper jams.

We recommend the use of label sheets that have a non-adhesive border around the label area. Make sure that the
release strength is enough to withstand temperatures of 225°C (437°F) and pressure up to 25 psi. The ability to withstand
these factors is important because the label sheet will be subjected to these 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. Label ties also prevent 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

15 mm

Reference Plate

12 mm

4.02 mm

Reference Plate

Labels 22

Load label sheets with the label end first. Use grain long paper instead of grain short paper, which tends to curl easily.

If a converter develops a grain short lab el sheet for duplexing, then test the sheet first to make sure it works 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. You may also use
the wiper when using the printer to print on one side of a label sheet or both sides of a sheet of paper. When ordering
a new cartridge, be sure to order the cartridge that includes the correct fuser wiper.

Primary rib pattern design guidelines for reference edge alignment

The function of the primary rib pattern is to provide the best support to the media during transport. If it is known that
the media will be touching a certain surface, then that surface must contain the primary rib pattern.

The feed path should guide the leading edge of the media into the primary guide surface and not the secondary surface.
This provides a determinate location for the leading edge of the media on the guide surface that provides the best
support.

The incidence angle of the leading edge of the media as it touches the primary guide surface should be no more than
30°. This eliminates media stubbing on the guides and reduces the amount of energy input into the media by the guide.

The primary rib pattern is to have the rib support extending out to between 3 to 10 mm from the edge of the paper
and 2 to 10 mm from the edge of the envelopes. This keeps the corners of the media stiff so that it cannot fold and
catch other surfaces in the printer. It also prevents the corners of the media from catching the inside surface of a paper
path rib.

The primary rib pattern should not have any ribs closer than 3 mm to the outside edge of paper and envelopes. This
keeps the media from stubbing into a rib that is too close to the edge of the media.

The maximum rib spacing of the primary rib pattern should not be greater than 20 mm. This keeps the leading edge of
the media flat as it moves through the system.

Labels 23

The following are the rib locations for the Lexmark MS710, MS711, MS810, MS811, MS812, MX710, MX711, MX810,
MX811, and MX812 printer models.

221.6

204.0

0.6

189.6

170.5

0.6

0.4

153.0

0.4

134.0

115.6

0.4

0.4

94.4

83.5

0.4

68.5

0.2

0.2

52.5

0.2

36.5

0.2

0.2

20.5

5.6

Reference
Edge

0.1

0.1

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 25.

Tissue‑backed, plain bond, or bond‑like, porous, lay‑flat liners are preferred. Liners constructed for use with high‑speed
laser printers (50 or more pages per minute) may not produce acceptable results.

A liner should bend easily and go back to its original flat state when released. If the form remains bent, then 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, then contact your Lexmark representative to verify which method your
printer uses to separate sheets of labels.

Labels 24

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, C792e, C792de, C792dte, C792dhe, C935, CS310n,
CS310dn, CS410n, CS410dn, CS510de, CX310n, CX310dn, CX410e, CX410de,
CX410dte, CX510de, CX510dhe, CX510dthe, T520, T522, T620, T622, T630,
T632, T634, T640, T642, T644, T650, T652, T654, T656dne, X203, X204, X215,
X264, X363, X364, X463, X464, X466, X540, X642e, X644e, X646e, X651, X652,
X654, X656, X658, X734, X736, X738, X792de, X792dte, X792dtfe, X792dtpe,
X792dtme, X792dtse, 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 machine
finish (MF) or English finish (EF) 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 produces high gloss surfaces that may be slick. Some supercalendered 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‑sensitive constructions use Kraft liners or bleached Kraft liners. Kraft liners are made from sulfate pulp
and are MF or machine glazed (MG). 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 25

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 inches) 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 edge 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 polyester 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 25.

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. For more information, contact your forms supplier.

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 up to 225°C (437°F) and
pressures up to 25 psi. Carefully test the stock to make sure it functions satisfactorily with your printer.

Note: Temperatures vary by printer. For more information, see the section for 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) and pressures
up to 25 psi for 100 milliseconds to prevent fuser damage.

Note: Temperatures vary by printer. For more information, see the section for your printer.

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. Solvent‑based topcoats
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. Carefully test the forms to make sure the topcoat functions satisfactorily with your printer.

Label design guidelines

Labels with a stripped edge matrix do not have the area around the outer edge of the cut sheet. Labels with a total
strip matrix do not have the die‑cut stock around and between the labels. This makes it easy 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 26

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, then make sure adhesive contamination does not occur. Labels use varying
levels and types of adhesive, as well as a variety of liner materials and facestock papers. Adhesive can ooze from all
label stocks. Make sure die‑cuts are free of adhesive stringers. To prevent adhesive contaminations, use zone coating
or pattern adhesive with a non‑adhesive border of about 1‑mm (0.04‑in.) or larger.

If zone coating is not used, then 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

Paper* (cut sheet or
dual web)

Vinyl

140–180 g/m

265–300 g/m

2

2

1.6 mm (0.0625 in.)

1.6 mm (0.0625 in.)

1.6 mm (0.0625 in.)

1.6 mm (0.0625 in.)

215.9 mm (8.5 in.) at leading edge

279.4 mm (11 in.) at driver edge

215.9 mm (8.5 in.) at leading edge

279.4 mm (11 in.) at driver edge

Polyester and other
face materials

* Use a non‑oozing adhesive.

Varies 1.6 mm (0.0625 in.)

1.6 mm (0.0625 in.)

215.9 mm (8.5 in.) at leading edge

279.4 mm (11 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, then print before removing the matrix.
If the matrix must be removed before printing, then 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 27

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

Waste strip 0.25 in (6.35 mm)

0.5 in.

12.7 mm

Waste strip

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 28

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

Labels 29

The following diagram shows a recommended label design for 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

Non-print area

0.33 in.

8.38 mm

Top perforation

Driver edge

11 in.

279.4 mm

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 30

• 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 25.

• 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.