Choosing the Right Thickness for Thermal Paper Rolls

Thermal paper rolls are a staple consumable used daily across industries like retail, catering, logistics, and healthcare. Many buyers notice that even for rolls of the same 80mm width, the outer diameter can vary, commonly between 60mm and 80mm. This key difference stems from the paper's thickness. This thickness is intrinsically linked to the roll's physical dimensions, directly impacting the total paper length, runtime, and overall cost.

First, it's important to know that thermal paper weight generally ranges from 45 gsm to 175 gsm, which corresponds to a thickness of approximately 47 μm to 180 μm. However, not all weights are commonly used.

The Application Primarily Dictates the Choice of Thermal Paper Thickness

• High-Frequency, Short-Term Use (e.g., Supermarket Checkouts): These scenarios don't require heavy paper. The common thickness range is 55-60 μm. A paper roll of this type, for instance, in an 80x80mm dimension, will yield a longer length. While it may come at a higher price point, it is more cost-effective for high-volume printing due to fewer changeovers.

• General Retail, Logistics, & Medical Documents: These applications require a balance of tactile feel and archivability. Paper in the 65-70 μm range, often termed standard thermal paper, is best suited for these uses.

• Long-Term Archiving: For records requiring extended longevity, paper with a thickness exceeding 70 μm is the preferred choice.

It's also crucial to note that different coating formulations can lead to varying print quality and preservation performance, even at the same thickness.

The Direct Impact of Thickness

The most direct effect of paper thickness is on the roll length for a given outer diameter. Thinner paper allows for a longer length to be wound onto the same-sized roll, whereas thicker paper results in a shorter length. 

For example:

• An 80x80mm roll at 55 μm thickness provides approximately 80 meters of paper.
• An 80x80mm roll at 70 μm thickness provides approximately 60 meters of paper.

How to Select the Right Thermal Paper Thickness

Your selection should be a balanced consideration of application needs, printer compatibility, and cost efficiency.

• Application: For high-frequency, short-term use (e.g., supermarkets, restaurants), opt for thinner rolls (approx. 55–60 μm). Their greater length reduces replacement frequency. The standard ≈65 μm paper offers a good balance of clarity and durability for general business and shipping documents. For documents requiring long-term storage or abrasion resistance, choose ≥70 μm paper to minimize fading and wear.

• Printer Compatibility: Always consult your printer/label maker's manual and perform a test print before bulk purchasing. This prevents jams from overly thick paper or paper tears and misfeeds from overly thin paper.

• Cost Efficiency: Compare the meterage per roll and cost per sheet. In high-volume, short-retention scenarios, thinner paper saves on replacement costs. For applications demanding high preservation, thicker paper is the more prudent investment.