DPD 4×4 vs 4×6 Direct Thermal Labels – UK Shipping Guide for Sellers (2026)

If you ship with DPD and Royal Mail (or you use more than one courier), label sizes can get confusing fast. Some platforms generate a compact square label, others produce a full 4×6 shipping label, and if your printer settings are even slightly off, you can end up with clipped barcodes, tiny text, or labels that do not scan cleanly. This is why many UK sellers keep asking the same question in 2026: do I need 4×4 labels, 4×6 labels, or both?

This guide makes it simple. We explain why DPD uses different label formats, what 4×4 labels are best for, when 4×6 is the safer default, and how multi-courier sellers avoid costly dispatch mistakes. If you sell on eBay, Amazon, Etsy, or your own website, the goal is the same: labels that print correctly, scan first time, and keep parcels moving without delays.

Why DPD Uses Different Label Sizes

DPD’s network is built around fast sorting and routing. In many cases, the key information DPD needs is a scannable barcode and routing data that helps parcels move through depots quickly. That is one reason you will often see DPD labels generated in a compact format.

By comparison, some shipping labels are more address-heavy. They prioritise a larger delivery address block, sender details, and extra service information. This is more common on full-size shipping labels used across multiple couriers and marketplaces.

So why does the 4×4 format exist? For many DPD shipments, a 4×4 label provides enough space for the barcode and routing elements while keeping the label compact and easy to place on smaller parcels. It can also reduce wasted label area when the label content does not require a full 4×6 layout.

What Is a 4×4 Thermal Label Used For?

A 4×4 thermal label is most commonly used when a courier or shipping tool generates a square-format label, which is often seen with certain DPD services. It is designed to print cleanly on 4-inch thermal printers and fit neatly on compact parcels without wrapping around edges.

Where 4×4 works well:

• Compact parcels where a full 4×6 label would overlap corners or crease
• DPD routing-style labels that focus on barcode scanning and depot sorting
• Sorting labels for internal workflows, such as batching, route separation, or staging areas
• Multi-courier setups where you keep 4×4 available for the services that require it

For sellers who use DPD regularly, keeping a small stock of 4×4 labels can prevent last-minute reprints and scaling issues when a platform outputs a square label format.

White 4×4 thermal labels are the simplest option when you need a clean square format for DPD-style labels.

What Is a 4×6 Thermal Label Used For?

A 4×6 thermal label (100×150 mm) is the UK’s most common shipping label size. It is widely supported because it provides enough space for full address details, service information, and a large barcode that scans reliably throughout the delivery journey.

Where 4×6 is the safer default:

• Full address labels where you want clear, readable delivery details
• Marketplace labels generated by eBay, Amazon, Etsy and many shipping apps
• Multi-courier compatibility when you switch between DPD, Royal Mail, Evri, UPS and others
• Royal Mail + DPD crossover where you want one standard label size that works across your dispatch workflow

Many UK sellers standardise on 4×6 because it reduces printing issues. If a label prints slightly smaller or larger, 4×6 still usually leaves enough room for barcodes and key text to remain readable and scannable.

White 4×6 thermal labels are a dependable choice for daily shipping, especially if you use more than one courier or platform.

DPD 4×4 vs 4×6 – Side-by-Side Comparison

When 4×4 Labels Can Cause Issues

While 4×4 labels work well in the right scenario, they are not always the safest choice. Problems tend to appear when label content is more detailed than the format allows.

• Crowded layouts – full delivery addresses and service notes can become cramped, making text harder to read.
• Barcode sizing – smaller barcodes may scan less reliably if the printer auto-scales the label.
• Platform mismatch – some marketplaces generate labels designed for 4×6, which can be clipped when forced into a 4×4 format.
• Cross-courier reuse – labels generated for Royal Mail or other couriers often do not translate well to 4×4.

For sellers who switch couriers or platforms, these issues are the main reason many default to 4×6 labels for day-to-day dispatch.

Which Label Size Is Best for Multi-Courier Sellers?

If you ship through more than one platform or courier, consistency matters. Using a single label size across your operation reduces errors and speeds up packing.

• Amazon – often outputs labels designed for 4×6, especially when address and tracking details are included.
• eBay – commonly supports 4×6 layouts for Royal Mail and courier services.
• Etsy – labels vary by service, but 4×6 remains the most flexible option.
• Shopify – depends on the shipping app and courier, with 4×6 widely supported.
• Royal Mail + DPD mix – 4×6 is the safest standard when using both couriers side by side.

For most multi-courier sellers, keeping 4×6 as the default and 4×4 as a backup for specific DPD services offers the best balance of flexibility and reliability.

Explore all available formats and sizes in our thermal labels collection to build a setup that suits your dispatch workflow.

Common Mistakes Sellers Make with DPD Labels

• Choosing the wrong size – forcing a 4×6 label into a 4×4 layout can cause clipping or unreadable barcodes.
• Incorrect printer scaling – automatic scaling settings can shrink barcodes and reduce scan reliability.
• Barcode truncation – cutting off quiet zones around the barcode can lead to failed scans.
• Using inkjet labels – inkjet paper can smudge, fade or peel, especially during courier handling.

Most of these issues are avoided by matching the label size to the courier output and using direct thermal labels designed for shipping.

Printer Compatibility for 4×4 and 4×6 Labels

Both 4×4 and 4×6 thermal labels are designed for standard 4-inch direct thermal printers commonly used by UK sellers. As long as the printer supports 4-inch wide media, switching between these sizes is usually straightforward.

• Zebra GK420 / ZD series – widely used for courier labels; supports both 4×4 and 4×6 roll-fed labels with a 1″ core.
• Citizen CL-S series – reliable desktop printers that handle both sizes well when media width and gap settings are correct.
• TSC DA / TE series – commonly used in warehouses and fulfilment centres; compatible with both label formats.

Tray and feed notes: always check whether your printer uses rear-feed or bottom-feed media. Make sure the sensor is set correctly for the label gap or perforation to avoid misfeeds or skipped labels.

Should You Keep Both 4×4 and 4×6 in Stock?

For sellers shipping at volume, keeping both label sizes available is often a practical decision rather than an extra cost.

• High-volume logic – different platforms and couriers can output different formats, even within the same week.
• Busy periods – during sales events or seasonal peaks, having both sizes prevents delays caused by reprinting or resizing labels.
• Avoiding dispatch delays – if one label size runs out, you can continue shipping without interruption.
• Cost control – buying both sizes in bulk keeps the per-label cost low and predictable.

Many established sellers default to 4×6 for everyday shipping and keep 4×4 on hand for specific DPD services.

Buying Labels in Bulk for DPD Shipping

If you ship daily with DPD, buying labels in bulk is usually more efficient than ordering small quantities repeatedly. Trade buyers and high-volume sellers benefit from consistent supply and stable pricing.

• Trade buyers – ideal for ecommerce brands, warehouses and 3PLs shipping multiple parcels per day.
• Bulk cases – boxed quantities reduce cost per roll and simplify reordering.
• Predictable supply – holding stock on site avoids last-minute shortages during busy weeks.
• No courier limits – unlike courier-supplied labels, you can order the quantity you actually need.

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Using Direct Thermal Labels with Mailing Bags

Direct Thermal labels work well on both cardboard boxes and mailing bags, as long as they are applied correctly.

• Poly mailing bags – apply the label to a smooth, flat area and press firmly to ensure full adhesion.
• Cardboard boxes – labels bond easily to clean, dry cardboard surfaces.
• Flat application – avoid placing labels over seams, folds or creases to prevent barcode distortion.

Using the right label size with the correct packaging helps couriers scan parcels quickly and reduces the risk of delays.

See suitable options in our mailing bags collection. Many sellers pair labels with standard grey mailing bags for everyday shipping.

DPD Label Sizes for eBay, Amazon and Shopify Sellers

Label size requirements can vary depending on where your order originates. Understanding these differences helps avoid reprints and packing errors.

• eBay sellers – most courier and Royal Mail labels default to 4×6, making it the safest option.
• Amazon sellers – address-heavy labels and tracking details usually suit 4×6, even when using DPD.
• Etsy sellers – labels vary by service, but 4×6 offers the most flexibility.
• Shopify stores – output depends on the shipping app and courier; 4×6 works across most setups.

Multi-channel sellers often standardise on 4×6 labels and keep 4×4 available only when a specific DPD service requires it.

Final Advice for DPD & UK Online Sellers in 2026

If you mainly ship small parcels with DPD and your platform outputs square labels, 4×4 labels can work well. However, for most sellers using multiple couriers or platforms, 4×6 remains the safest default.

Choose 4×4 when your DPD service outputs a square label and parcel size is compact.
Default to 4×6 when you want one label size that works across DPD, Royal Mail and marketplaces.

Maintaining independence from courier-supplied consumables gives you more control over costs, supply and daily dispatch. Choosing the right label sizes — and keeping the right stock on hand — helps keep your shipping operation smooth in 2026 and beyond.

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