Guide · Troubleshooting
Fix common shipping label printing problems
Updated 12 October 2026 · 7 minute read
A label that will not scan can mean a delayed or returned parcel, so it is worth getting printing right. Most problems come from a handful of causes: scaling, paper size, print quality and the file itself. Find your symptom below and work through the fixes in order.
First, the quick checks
Before digging into a specific problem, check these five things. They solve most cases:
- Print at Actual size (100%), never “Fit to page”.
- Paper size in the print dialog matches the paper in the printer (A4 for sheets, your roll size for thermal).
- You are using the original PDF from the seller panel, not a screenshot or a photo of a screen.
- Print quality is not set to draft or economy.
- You printed one test label and scanned it with a phone before printing the batch.
The barcode will not scan
- Scaling. If the page was shrunk to fit, the bars are thinner than intended. Reprint at 100%.
- Faint or streaky print. Low ink or toner, a dirty print head, or a worn thermal roll. Run the printer’s cleaning routine, replace the cartridge or roll, and raise the print quality.
- Wrinkles and bubbles. A creased label distorts the bars. Stick it on flat, smoothing from the centre outwards.
- Glare. Glossy tape reflects light into the scanner. Use matte tape, or leave the barcode uncovered.
- Too small. If you print four labels per A4 sheet, try two per sheet for a larger barcode.
The label is cut off or too small
- Wrong paper size. Check that the print dialog says A4 for sheet printing, or your roll size for thermal. A Letter page clips an A4 layout slightly.
- Fit to page. This shrinks the whole page and leaves large margins. Switch to actual size.
- Thermal driver size. If a thermal printer cuts labels, set the driver’s default paper size to your roll, for example 100 × 150 mm.
Blank pages or labels come out
- Thermal printer skipping a label. Calibrate the printer so it finds the gap between stickers.
- Extra blank page on A4. Usually a margin or scaling issue. Print at actual size and check the page range in the dialog.
- Empty preview. If the PDF preview itself is empty, process the file again, or open the original PDF to confirm it is not damaged.
The print window does not open
Direct Print opens the finished PDF in a new browser tab. If you press it and nothing appears, the browser has blocked the pop-up. Look for a small “pop-up blocked” icon near the address bar, allow pop-ups for the site, and press the button again. As a workaround you can press Download, open the saved PDF and print it from your PDF viewer.
The SKU or courier is missing
The tool reads the SKU, quantity and courier from the text inside your PDF. A scan, a photo or a screenshot has no readable text, so those details cannot be found. Download the label again from the seller panel and use that original file.
The file will not open
- Check that it is a normal PDF and not a ZIP, a picture or a web page saved with a PDF name.
- If it is password protected, remove the password first with the Unlock PDF tool.
- If it is damaged, try Repair PDF, which rebuilds what it can read.
Prevent problems next time
- Save your printer settings (actual size, correct paper) as a default preset.
- Test-print one label whenever you change printer, roll, paper or ink.
- Keep a few spare labels or sheets, so a failed print never delays shipping.
- Store thermal rolls in a cool, dry place.
Frequently asked questions
Why does my label barcode not scan?
The usual causes are scaling (fit to page was on), a faint print from low ink or a dirty print head, a wrinkled label, or glare from glossy tape. Print at actual size, improve print quality, and re-test.
Why is my printed label smaller than expected?
Fit to page or shrink to fit was selected in the print dialog. Choose Actual size or 100% instead.
Why does the print window not open when I press Direct Print?
Your browser blocked the pop-up. Allow pop-ups for the site and press Direct Print again.