How to Print a Packing Slip on a Thermal Printer
Printing a packing slip on a 4×6 thermal printer is simple once three settings are right: paper size, scale and margins. This guide covers each, the mistakes that waste labels, and a free maker to create the slip itself.
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Quick Answer
Make your 4×6 packing slip
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Print at Actual Size / 100% on 4×6 stock — not “Fit to page.” Long orders continue onto extra 4×6 pages instead of shrinking text below 7 pt.
Before you print: use a 4×6 page from the start
The most common reason a packing slip looks wrong on a thermal printer is that it began as a Letter or A4 page. Squeezing a full-page document onto a 4×6 label makes the text tiny. Starting with a page that is already 4×6 avoids that — the packing slip maker on this page creates exactly that, with order details laid out for the smaller space.
Then check your stock: direct-thermal printers need heat-sensitive label or paper stock (thermal-transfer printers also need a ribbon). Regular office paper won’t mark on a direct-thermal printer.
The three print settings that matter
- Paper size: choose 4×6 in (100×150 mm) — add it as a custom size in the printer driver if it isn’t listed.
- Scale: Actual Size / 100%. Turn off “Fit to page” and “Shrink to fit.”
- Margins: None or Minimum, and headers/footers off if you print from a browser.
Where you find them depends on the app and operating system:
- Chrome / Edge: open the PDF, press Ctrl/Cmd+P, choose the printer, then More settings → Paper size 4×6 (or your custom size), Margins None, Scale 100%.
- Adobe Acrobat / Reader: under Page Sizing & Handling choose Actual size.
- macOS: in the print dialog open Paper Size → Manage Custom Sizes, add 4 × 6 in, and set Scale to 100%. To make it the default, choose the size in Printers & Scanners (Rollo documents these steps for its printers).
- Windows Printing Preferences: add or select a 4×6 in (100×150 mm) paper size in the driver so it appears in every app.
Packing slip printing problems and fixes
| Problem | Most likely cause | Fix |
|---|---|---|
| Prints tiny with large margins | Scaled to fit a larger page | Actual Size / 100%; paper size 4×6. See printing too small |
| Edges cut off | Wrong paper size or margins | Paper 4×6 in, margins none |
| Blank label after each slip | Page taller or shorter than the label; calibration | Match paper size; recalibrate media |
| Rotated sideways | Orientation mismatch in driver | Set Portrait; try rotating in the driver |
| Faint or streaky text | Low darkness, dirty printhead, wrong stock | Run the printer test |
| Order runs onto page 2 | Many items for one 4×6 page | Expected: each page is its own 4×6 print |
Still stuck? Read why thermal prints are faint or why the printer feeds extra labels. Using a specific printer? See the Rollo and Munbyn setup notes, or ShipStation’s built-in 4×6 packing slip option.
Sources and official help
These are the vendors’ own help pages behind the steps above. Menu names and settings change over time; check the vendor’s current documentation for your account or printer model.
- Rollo Support: select a default 4×6 label size on Mac
- Rollo Support: adjusting label margins
- Munbyn Help Center: why doesn’t my label print correctly?
Found something out of date? Tell us and we’ll correct it.
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Frequently asked questions
How do I print a packing slip on a thermal printer?
Create or download a packing slip that is already 4×6, open it, choose your thermal printer, set the paper size to 4×6 in (100×150 mm), the scale to Actual Size / 100% and margins to none, then print. Test one slip before printing a batch.
Can I print a normal packing slip on a 4×6 thermal printer?
You can, but a Letter or A4 packing slip scaled onto a 4×6 label is usually too small to read. It’s better to create a slip that is 4×6 from the start, like the one the maker above produces.
What paper size should I choose for a packing slip on a thermal printer?
Choose 4×6 in (100×150 mm) — the same size as a standard shipping label. If it’s missing from the list, add a custom paper size in the printer driver.
Why does my packing slip print with huge margins?
The print dialog is scaling the page to fit. Set the scale to Actual Size / 100% and turn off Fit to page, and make sure margins are set to none.
Do I need special paper or labels for a packing slip?
You need stock your printer can use: heat-sensitive (direct-thermal) 4×6 label or paper stock for most shipping-label printers. Adhesive backing is optional for a slip that goes inside the box.
Why does my thermal printer feed a blank label after the slip?
Usually the page size doesn’t match the loaded label or the printer needs to be recalibrated to the stock. Match the paper size to your label and run your printer’s calibration routine.
More for sellers who print on 4×6
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Make a 4×6 Packing Slip