Ordering blank or custom self-adhesive labels can sometimes feel a bit technical and confusing, particularly the first time. You may come across terms like core, plate and cutter, and wonder what they mean. We’ve crafted this guide to help you understand the main terms you’ll encounter and why they matter.
What is a Core?
A core is the cardboard or plastic tube in the centre of a roll of labels. It determines how the roll fits on dispensers and printing machines. Cores come in standard diameters, commonly 25mm, 38mm and 76mm. The core size you need depends on your printer or applicator.
Why does the core matter?
- Compatibility: Your printer’s spindle or dispenser requires a specific core diameter. Using the wrong core can cause jams or misfeeds.
- Roll length: Larger core sizes usually mean fewer labels per roll but can be necessary for heavy-duty machines.
- Transport and storage: Core material affects roll rigidity; plastic cores are more durable for automated lines.
When ordering, tell the supplier the core diameter your equipment accepts and whether you prefer cardboard or plastic cores; at DIGI we will be able to advise you on which will suit you best.
What is a Plate?
A plate is a printing tool used in some printing processes, such as flexographic printing. It transfers ink onto the label material. The plate contains the design to be printed and is usually made from photopolymer material.
Why does the plate matter?
- Setup cost: Plates are a one-time production cost per design. For short runs, plate costs can make custom printing more expensive per label. However, for higher volume label printing they become cost-effective.
- Durability: Good-quality plates produce consistent prints over long runs, making them cost-effective for medium to large orders.
- Detail and colour: Plate-based processes reproduce sharp text and solid colours reliably, particularly for single-colour or spot-colour jobs.
At DIGI we store our clients’ plates for re-use, helping to keep costs down, reduce waste and reduce lead time for repeat orders.
What is a Cutter or Die?
A cutter, or die, is the tool that shapes each label. You may hear the term ‘die-cut’. It can be a steel rule die for complex shapes, a rotary die for high-speed roll production, or a digital/laser cutter for short runs and variable designs.
Why does the cutter or die matter?
- Shape and precision: A properly made cutter ensures consistent label shape and accurate registration so labels peel and apply correctly.
- Setup cost: Steel dies have an upfront cost; for low quantities digital cutting may be cheaper.
- Edge quality: Rotary and steel dies give clean edges suitable for pressure-sensitive labels; digital cutting is ideal for prototypes and flexible runs.
Like plates, we store the die for your re-orders, keeping waste, time and cost down.
Why You Might Need These Items
- Cores: Needed for feeding rolls through printers, dispensers, and applicators.
- Plates: Needed for certain printing methods and an important factor in setup cost and lead-time. Good for consistent, repeat designs at scale.
- Cutters: Needed to produce the final label shape. Choice affects cost, lead-time, and edge finish.
Choosing a trusted and reliable label supplier like DIGI that stores your plates and dies in case you need to reorder, can make a huge difference to your experience and pocket in future!
Summary
- Know your equipment: If your ordering blank labels for your label printer, Scales or Wrapper, provide the model so your supplier can recommend the correct core and roll format.
- Be aware of quantity vs setup cost: For runs under a few hundred rolls or frequent design changes, digital printing and cutting often save money. However, if you are ordering more, or are likely to reorder often, plates and dies are more cost-effective in the long-run and may just make the initial set-up charge higher.
- Material and adhesive: Let your supplier know how your label will be used, i.e. the surface it will be applied to and the environment it will be in. This will help the supplier recommend a label material (e.g. paper, polypropylene, vinyl) and adhesive type (e.g. permanent, removable, freezer-grade).
- Colours and finish: At DIGI, our in-house graphic design team can help you prepare your artwork for press, or design it from scratch. They can guide you through choosing from spot colours, CMYK or special inks, and an array of finishes like gloss, satin or matte.
- Lead times: Setup items (plates, dies) add to lead time. Ask about lead time for first run and for repeat orders if plates/dies are stored.
- Storage options: If you’ll reorder regularly, ask whether the supplier offers plate and die storage and whether reactivation incurs a fee. At DIGI, we store your plates and dies for four years and don’t charge for this service. After that period, we will offer them to you.