Technology guide
Thermal Transfer Overprinting (TTO)
Thermal transfer overprinting (TTO) prints dates, text and barcodes onto flexible packaging by melting ink off a ribbon. It's a fixture on flow-wrap, pouch, sachet and labeling machines, where the film runs over a roller the printhead can press against.
How it works
A TTO printer presses a heated printhead against an ink ribbon, sandwiching the ribbon and the packaging film against a roller or flat platen. Each dot on the printhead heats individually, melting ink from the ribbon onto the film to form sharp text, dates and barcodes.
It runs in two modes: intermittent, where the film stops and the printhead moves across it, and continuous, where the ribbon is sped up to match moving film. Either way, the printhead touches the ribbon and needs a firm surface behind the film.
TTO ribbon types
Good for: General coding where the code doesn't face much rubbing
Good for: A balance of durability and print quality on most films
Good for: The most durable codes, for packs that face rubbing, heat or chemicals
| Ribbon | Good for |
|---|---|
| Wax | General coding where the code doesn't face much rubbing |
| Wax-resin | A balance of durability and print quality on most films |
| Resin | The most durable codes, for packs that face rubbing, heat or chemicals |
Match the ribbon to the film and how the pack will be handled; the ribbon is TTO's main consumable.
Best for
- Flexible films — flow-wrap, sachets, pouches, lidding
- High-resolution text, real-time date codes, and barcodes
- Pre-printed or blank labels on labeling machines
- Crisp, durable codes where ink might smear on film
Considerations
- Needs a roller or platen behind the film: suited to film on packaging machines, not rigid or curved products
- Consumes ribbon, matched to the film
- The printhead contacts the ribbon, so it's a wear part
How it compares to thermal inkjet
TTO and thermal inkjet (TIJ) both print sharp codes on flexible film, in different ways. TTO presses a ribbon against the film and needs a roller or platen behind it, which suits flow-wrap and pouch machines. Thermal inkjet doesn’t touch the pack: it prints up to 6 mm from the surface with Odyssey solvent ink on film and foil, and the same printer codes cartons, cases and rigid containers with the right ink. Plenty of lines use both. Tell us your packaging and we’ll help you map the right method to each part of it.
TIJ Print Solutions specializes in thermal inkjet. We’re happy to help you choose the right technology for your line — even when that conversation starts here. Explore our coding & marking inks.
Not sure which technology fits your line?
Tell us your product, substrate, and line speed and we’ll help you weigh the options — and show you where thermal inkjet is the simplest, lowest-maintenance fit.
Frequently asked questions
What is thermal transfer overprinting used for?
TTO is used for high-resolution coding — dates, text, and barcodes — directly onto flexible packaging films and labels, such as flow-wrap, pouches, and lidding.
Is TTO the same as thermal inkjet?
No. TTO melts ink from a ribbon onto film with a heated printhead pressed against the pack. Thermal inkjet (TIJ) fires ink drops from a cartridge without touching the pack, onto film, foil, cartons, cases and rigid surfaces, with the ink matched to the material.
What's the difference between wax, wax-resin and resin ribbons?
Durability. Wax suits general coding, wax-resin balances durability and print quality, and resin gives the toughest codes for packs that face rubbing, heat or chemicals.
What's the difference between intermittent and continuous TTO?
In intermittent mode the film stops and the printhead moves across it. In continuous mode the film keeps moving and the ribbon is sped up to match it. The packaging machine decides which you need.
Does TPS sell TTO printers or ribbons?
No. We supply thermal inkjet printers and Odyssey inks, which also code film and foil. We're happy to help you compare.