Fix a printer that skips labels in Crunchtime Labels

If your Zebra label printer skips labels, prints across the gaps between labels, or shows error lights when you print from Crunchtime Labels, its sensors have likely lost track of where each label starts and ends. You can fix this by running a Smart Calibration on the printer. The steps in this article are for Zebra ZD-series printers, such as the ZD410.

Why does my Zebra printer skip labels?

Your printer uses sensors to find the start and end of each label. When those sensors are out of alignment, you may see one or more of these symptoms.

• Labels are skipped
• Text prints across the gap lines between labels
• Text is misaligned on printed labels
• Red lights flash when you send a print job

Sensors usually lose alignment for one of these reasons.

• You loaded a label roll of a new size
• Labels were pulled out of the printer by hand while it was locked
• Dust built up on the gap sensors

A Smart Calibration makes the printer recalculate its baseline measurements. During calibration, the printer detects your media type, such as gap, black mark, notch, or continuous labels, and measures the media.

How do I run a Smart Calibration?

Run the calibration from the buttons on the printer itself. Follow these steps in order.

1. Check the label roll. Make sure the roll is loaded properly and threaded under the media guides, and that the top cover is latched closed
2. Turn on the printer. Press Power, then wait until the diamond-shaped Status light is steady. The light is usually solid green, but it can also be red or amber if the printer is in an alignment error
3. Start the calibration. Press and hold Pause and Cancel at the same time for two seconds, then release both buttons
4. Wait while the printer feeds labels. The printer feeds a few blank labels while it measures the backing material and adjusts its sensors
5. Tear off the blank labels. When the printer stops feeding and the Status light turns solid green, tear off the extra blank labels. Your printer is ready to use

Do I need to calibrate every time I change the label roll?

You don't need to calibrate again each time you replace the roll once you've calibrated for a specific type of label. While it prints, the printer automatically measures the labels and adjusts for small changes.

Run a new calibration when you switch to a label roll of a different size, or when you see any of the symptoms described earlier in this article.

Tip: After you install a new roll from the same batch, press Feed, the button between Pause and Cancel, once or twice to sync the labels. The printer is then ready to continue printing.

Get additional help from Crunchtime Support

If your printer still skips or misaligns labels after calibration, contact Crunchtime Support in any of these ways.

• Chat with the Ops Execution AI Support Chatbot
• Submit a request through the Crunchtime support portal
• Email Crunchtime Support at support@crunchtime.com

To help the team resolve your issue faster, include these details in your request.

• A clear description of the issue
• Your printer model, such as ZD410
• The troubleshooting steps you've tried so far
• Photos or videos of the issue