Print 100×150 mm shipping labels on Zebra ZD220, ZD230 and ZD421

Courier portals deliver shipping labels as PDF files. With the right paper size in the driver and the right scaling when you print, a Zebra ZD220, ZD230 or ZD421 prints them full size on 100×150 mm (4×6 in) labels, with barcodes that scan first time. The steps work for any courier.

Before you start

Most shipping labels are direct thermal: the print appears where the printhead heats the label, so no ribbon is needed. On a thermal transfer model (ZD220t, ZD230t or ZD421t), remove the ribbon for direct thermal labels and set Printing mode to Thermal Direct in the driver.

A 100 mm wide label fits all three printers: the ZD220 and ZD230 print up to 104 mm wide, the ZD421 up to 104 mm at 203 dpi and 108 mm at 300 dpi. Check that the roll fits too: up to 127 mm in diameter on a 12.7 or 25.4 mm core. Rolls on 38.1 mm cores need Zebra's media roll adapters; the ZD421 also has adapters for 50.8 and 76 mm cores.

No driver yet? Install it first with Install the ZDesigner driver on Windows 11.

Load the labels and calibrate

1. Load the roll with the printable side facing up. Shipping labels have gaps between them, so on a ZD220 or ZD230 leave the movable media sensor in the default centre position.
2. Close the cover and calibrate so the printer learns the 150 mm label length.
3. On a ZD220 or ZD230: with the STATUS light steady green, hold FEED. The light flashes once, then twice; release straight after the double flash. The printer feeds a few labels and is ready when the light is steady green.
4. On a ZD421: check the sensor position and calibrate as described in ZD421 calibration.

Video: Zebra Technologies

Set the paper size in the ZDesigner driver

Windows needs to know the label size, otherwise it sends an A4 or Letter page and the label comes out tiny or cut off.

1. Open Settings › Bluetooth & devices › Printers & scanners, choose your ZDesigner printer and open Printing preferences.
2. On the Page Setup tab, go to Media Settings and set the label to 100 mm wide and 150 mm high. Change the units to mm if needed.
3. Under Print Options, check that Printing mode is Thermal Direct for shipping labels without ribbon.
4. Leave Rotation on the Page Setup tab at its default for now. Change it only if the test label prints sideways or upside down.
5. Click Apply and OK.

Choose the label format in the courier portal

Most courier portals let you choose a label format. If yours offers one, pick the label printer format: names vary, for example 100×150, 4×6, A6, thermal or label printer. A label-sized PDF prints sharp and full size.

If the portal only creates A4 pages, the whole page would be shrunk onto one label. Look in your account or print settings for a label printer or A6 option, or ask the courier how to get labels in 100×150 mm format.

Print the PDF at the right size

1. Open the PDF and choose Print.
2. Select your ZDesigner printer. The paper size should show 100×150 mm, as set in the driver.
3. Choose the scaling option that fits the PDF to the paper size. Zebra recommends this for PDFs; the name differs between programs, such as fit, fit to page or shrink to printable area. If the PDF is already exactly 100×150 mm, actual size (100 %) works too.
4. Let the program pick portrait or landscape automatically, or choose portrait.
5. Print one label first and check it before printing a batch.

Adjust darkness and speed if needed

Print quality depends on three things working together: darkness (heat), print speed and the labels themselves. Zebra recommends testing combinations to find the best result.

• Pale print or barcodes that won't scan: raise Darkness one step at a time under Print Options in the driver's Printing preferences (or in your label software), and print again.
• Still not crisp: lower Speed, also under Print Options. Label manufacturers may recommend a speed below the printer's maximum.
• Bars look bold and run together: lower the darkness again.

Persistent pale print can also come from a dirty printhead. See ZD220/ZD230 lights and errors for print-quality fixes.

Test the label

• Scan every barcode on the label with a scanner or phone.
• Check that no edge of the address or barcodes is cut off.
• Check that the next label starts cleanly, with no blank label in between.

Common problems