Label size directly affects logistics costs, print quality and compatibility with courier and marketplace systems. This guide presents the most popular thermal label sizes with practical applications.

The 5 Most Popular Thermal Label Sizes

100×150 mm

Shipping Label

The most popular size for courier, e-commerce and InPost, DHL, DPD, UPS, FedEx shipments. Fits marketplace integrations (Allegro, eBay, Amazon, BaseLinker).

Printer: Zebra ZD220, ZD420, GK420d, GC420d.

100×170 mm

Long Shipping Label

Longer variant for international shipments requiring additional info (CN22, CN23 customs, barcodes, return address). Used by GLS, DPD EU.

Printer: same as 100×150.

58×40 mm

Mini Shipping / Product

Compact label for small parcels (jewelry, cosmetics, small electronics). Also used on store shelves and for price labeling.

Printer: portable – Zebra ZQ320, Brother PT-P710BT.

40×25 mm

Product Label

Small item labeling in retail, product codes, prices. Often used with code scanners (EAN-13, Code 128).

Printer: Zebra GK420t, TSC TE200.

80×50 mm

Address / Courier Small

Small courier labels (return packages, samples). Also for marking samples in laboratories.

Printer: any desktop with 4-inch printhead.

50×30 mm

Warehouse / Pricing

Warehouse location labels, bin labels, fast price changes in retail.

Printer: Zebra GX430t, Brother TD-4550.

Full Thermal Label Size Chart (Industry Standards)

Size (mm) Typical application Labels per roll
100×150Courier (InPost, DHL, DPD), marketplaces500–1000
100×170EU international shipments, customs documents450–900
148×210 (A5)A5 labels, SSCC palette labels250–500
102×152Export labels (US/UK)500–1000
80×50Small shipments, sample labeling1500–2000
58×40Mini courier, retail pricing1800–2500
50×25Product labeling, price labels3000–5000
40×25Barcode labels, small products4000–6000
32×25Round labels for cosmetics, jewelry5000–7000
30×20Price labels, small packaging6000–8000

How to Choose the Right Size?

1. Check Your Printer

Every thermal printer has a maximum print width (most common: 4", i.e. 104 mm). Labels wider than 104 mm will not print. Narrow desktop printers (2") support only up to 58 mm.

2. Match to Carrier Requirements

Each carrier has specific format requirements:

  • InPost Paczkomaty: 100×150 mm (accepts 100×140 mm as minimum)
  • DHL Express: 100×150 mm or 100×200 mm
  • DPD: 100×150 mm
  • GLS: 100×150 or 100×170 mm
  • UPS: 4×6 inches = 102×152 mm
  • Allegro Smart: 100×150 mm

3. Consider Information Density

The more text/barcodes/graphics, the larger the label needed. QR codes require a minimum of 15×15 mm to be reliably scanned.

4. Calculate Cost Per Label

Smaller labels come with more per roll, which reduces roll change frequency and the per-label price. For volume above 10,000 units/month it pays to order custom-cut sizes.

Tip: Custom Size

If standard sizes don’t fit your application, we cut labels to any custom size at no extra charge. Minimum order: 10,000 units.

Roll Core and Outside Diameter

In addition to label dimensions, you also need to match the roll to your printer:

  • Core diameter: 25 mm (1") – desktop, 40 mm (1.5") – industrial, 76 mm (3") – large industrial
  • Maximum roll outside diameter: 127 mm (5") for desktop printers; 203 mm (8") for industrial ones

Looking for a specific size?

We produce over 120 standard thermal label sizes as well as custom cuts for any application. Fast delivery, free samples.

Request a Quote +48 503 179 658

See Also