Easy-To-Apply Cable Labels Solve Maintenance Issues

In complex cabling environments such as data centers, telecom closets, and industrial control panels, clear labeling is essential for identifying and organizing wires. However, manual label application can be error-prone and time-consuming, leading to increased labor costs, extended downtime, and operator frustration. Labels can also degrade over time, especially in frequently accessed environments, with adhesive failures and smeared ink resulting in missing or illegible labels.

This article examines the common challenges technicians face when labeling cables and performing routine service. It then introduces self-laminating labels from HellermannTyton and shows how these solutions’ innovative design enables fast application of long-lasting labels. The tools and software used to print these labels before installation will also be discussed.

Cable labeling for frequently serviced environments

In crowded connection environments, easy cable identification is vital for fast servicing and troubleshooting. Clear labeling at both ends of a cable eliminates doubt about the cable’s identity and avoids the need to trace it across long runs or through openings in chassis, harnesses, or walls. These labels must be securely fastened to be effective. By simplifying cable identification, systems also become safer for technicians. For example:

• Clear labeling promotes correct connections and helps prevent harm to equipment or personnel.
• Labeling at both ends reduces the need for manual cable handling when locating and tracing wires; unnecessary handling can cause damage that shortens a cable’s operating life.
• Labeling communicates the function of a cable. If a cable carries power, for example, appropriate precautions can be taken when handling is required.

Self-laminating wrap-around labels offer a reliable, inexpensive option for manual application in dense cable layouts. The sticker-type design adds negligible bulk to the cable and protects the identification code with a built-in laminate cover. This laminate is typically resistant to water, dirt, and abrasion, helping ensure that codes remain legible over the cable’s lifetime. The two-stage wrapping process also promotes secure, long-lasting attachment without requiring additional fasteners or application tools.

Manual cable labeling challenges

Despite the advantages of self-laminating wrap-around labels, their adhesive backing can lead to difficulties during application. The overall process of manual labeling can be significantly slowed by something as trivial as having fingernails trimmed too short. Closely spaced labels on the backing liner can be difficult to peel, resulting in wasted time during servicing activities.

Butt-cut labels exacerbate this issue and also present challenges for smaller wire gauges due to the inherent bend radius of the label material. The smaller the wire gauge, the more difficult manual application becomes. When labeling cables in large quantities, these inefficiencies compound, increasing labor costs and the likelihood of errors.

Large-scale labeling also introduces challenges when marking identification codes. Portable label makers are available, but printing can be slow, particularly when codes must be typed individually.

Handwriting is also an option, but it presents its own problems. Writing fatigue and improper marker usage can result in illegible handwriting or ink that smears or fades over time. These issues may ultimately render the labeling effort ineffective.

An innovative approach to self-laminating labels

By modifying the standard design for self-laminating wrap-around labels, HellermannTyton has addressed the operational issues associated with manual application. Its TabTags self-laminating labels (Figure 1) incorporate an ergonomic tab that acts as both an anchor point for wrapping and a self-dispensing mechanism for easy removal from the backing liner. Plus, the labels are discreetly spaced, allowing individual labels to be removed without disturbing others.

Figure 1: TabTags are quickly installed using a four-step process. (Image source: Kenton Williston, based on HellermannTyton source material)

Referencing Figure 1, Step 1 shows how bending the liner exposes the tab, allowing the label to be quickly separated. In step 2, the tab is anchored to the cable, enabling a straight wrap around even small-diameter wires without the slippage that often occurs during initial placement. From step 3 onward, the application proceeds like a standard self-laminating wrap-around label: the printed portion is wrapped around the wire, followed by the laminate section that protects the code print.

By removing the common obstacles to picking labels from backing and applying them to cables, the TabTags system enables roughly 12% more label applications per hour, with reliable, long-lasting results. This increased production output leads to significant time and cost savings for the required labor.

A variety of label sizes covering simple to complex installations

The TabTags family includes several options designed to accommodate different cable types and identification code requirements. The 596-12201 (Figure 2) is the largest variant, measuring 25.4 × 39.6 mm. The increased width supports longer identification codes for scenarios where cables require more detailed or easier-to-interpret designations. The length makes these labels suitable for larger cables with an outer diameter of 2.5 mm to 7.6 mm, including RG6 coaxial, HDMI, CAN bus, and standard Ethernet cables.

Figure 2: The large 596-12201 TabTags labels are arranged three per row with 5000 units on each roll. (Image source: HellermannTyton)

Conversely, the 596-12203 (Figure 3) is the smallest TabTags variant, measuring 12.7 mm × 20.8 mm. The narrower width supports concise codes in simpler systems or where there are space constraints on label width. These labels are designed for small-diameter cables such as multi-fiber push-on (MPO) fiber optic, slim and super-slim Ethernet, and USB cables with outer diameters up to 4.3 mm.

Figure 3: Serving smaller cable diameters, the 596-12203 TabTags labels are arranged in rows of six for a total of 10,000 units per roll. (Image source: HellermannTyton)

HellermannTyton also provides additional TabTags options that support short codes on thicker wires and long codes on thinner wires. All products in the family are manufactured from white and transparent 100B vinyl with acrylic adhesive. They are ultraviolet (UV) resistant and have an operating temperature range of -40 to +96°C, enabling robust performance in harsh environments.

Streamlining label printing with colorful options

A critical step in employing the TabTags system is ensuring that cable identification codes are clearly printed before installation. The TT230SM (556-00230) printer (Figure 4) is purpose-built for this task. Its lightweight, compact form factor enables transport alongside standard technician equipment.

Figure 4: The TT230SM is a compact desktop printing solution for quickly producing multiple labels with minimal setup time. (Image source: HellermannTyton)

The printer’s features include:

• a 300 dots-per-inch (dpi) print head for high-resolution label printing
• a highly accurate sensor that eliminates the need for calibration during label changes, saving time and reducing error
• fast print speeds for efficient production of large label batches
• an LCD user interface that simplifies setup, diagnostics, and adjustments

The TT230SM can be purchased as a kit (556-00239) that includes the necessary cables for power and computer connectivity, a label caddy for easier handling, a black thermal transfer ribbon, TagPrint Pro label design software, and a durable hard-shell carrying case.

Thermal transfer ribbons are also available separately in a variety of colors, including standard black, such as the TT822OUTSM (Figure 5). This 15 m resin-based ribbon provides excellent print durability with chemical and abrasion resistance up to +82°C. A built-in cleaning mechanism extends printhead life, helping reduce maintenance costs across the HellermannTyton printing ecosystem.

Figure 5: The TT822OUTSM 15 m thermal transfer ribbon offers excellent print durability. (Image source: HellermannTyton)

Simplify labeling with TagPrint Pro

TagPrint Pro is an essential software tool for realizing the full benefits of HellermannTyton printers. Compatible with Windows operating systems, it supports automated printing of multiple labels with visual previews. This streamlines the process of creating fresh labels for replaced cables or generating large batches for new installations.

Complete system label requirements can be grouped under a single file name, allowing users to locate specific labels visually or by part number at the time of printing. This eliminates the need to search reference materials manually, as TagPrint Pro provides that service. The software also supports bar code, QR code, and graphic printing (Figure 6) to accommodate applications beyond standard text labels.

Figure 6: TagPrint Pro offers a streamlined printing environment for large systems requiring many labels. (Image source: HellermannTyton)

Conclusion

It is critical to have clear, effective cable labeling to promote safe operation and reduce the time and cost associated with servicing frequently accessed systems. HellermannTyton’s TabTags system supports these goals with an ergonomic tab that improves label handling and streamlines application to increase operator efficiency. In combination with the associated printing hardware and software, this labeling system enables clear, robust, cost-effective cable management across a wide range of applications.