What size are Royal Mail shipping labels?

Royal Mail shipping labels are typically printed in the standard format 101.6 × 152.4 mm (4″ × 6″), which is used by Click & Drop for most parcel and business despatch labels.

Can I use my own labels with Royal Mail Click & Drop?

Yes. You can print Royal Mail labels onto compatible third-party direct thermal labels, provided the label size and construction match the expected format and the print quality is clear and scannable.

Do Royal Mail labels need to be perforated?

Perforation is strongly recommended for shipping workflows. It allows clean separation during packing, reduces tearing, and helps maintain consistent handling — particularly in higher-volume despatch operations.

What type of printer do I need for Royal Mail thermal labels?

You’ll need a direct thermal label printer that supports the 4″ × 6″ format. Most desktop shipping printers are suitable.

Are all direct thermal labels the same?

No. Differences in coating consistency, die-cut accuracy, adhesive performance and roll construction can affect print darkness, barcode definition and feed reliability. For customers with specific chemical or handling requirements, it is also important to understand the difference between BPA-free and phenol-free materials.

Royal Mail Thermal Labels

Click & Drop Shipping Format (formerly Despatch Manager Online / DMO)

Royal Mail business users now print the majority of shipping labels through Click & Drop (formerly known as Despatch Manager Online, or DMO).

For many e-commerce sellers, fulfilment operations and mailrooms, this has made the format and quality of thermal shipping labels more important than ever. Labels must print clearly, feed reliably through desktop printers, and remain legible throughout the delivery process.

This insight explains what Royal Mail shipping labels actually are, why the format matters, and what to look for when sourcing compatible direct thermal labels.

The Format Choosing Labels

Thermal printer producing a Royal Mail shipping label

The Royal Mail Shipping Label Format

Royal Mail parcel and business despatch labels are produced using direct thermal printing, meaning no ribbon or ink is required. The format used by Click & Drop and associated systems is consistent and well established.

Label size: 101.6 × 152.4 mm (4″ × 6″)
Format: Perforated between each label
Print method: Direct thermal
Typical use: E-commerce despatch, fulfilment centres and business mailrooms

Royal Mail’s software layouts are designed around this specification. Using labels that match the correct size and construction ensures that addresses, barcodes and service information appear in the expected positions.

Why the Exact Format Matters

Shipping labels play a critical role in both despatch efficiency and downstream scanning within Royal Mail’s network. Small differences in label specification can have a noticeable operational impact.

Layout accuracy: Correct sizing ensures text and barcodes print in the intended positions.
Perforation: Clean separation of labels during packing, without tearing or curling edges.
Printer performance: Accurate die-cutting and roll construction help labels feed smoothly through desktop thermal printers.
Scan reliability: Clear, well-defined barcodes support automated handling and tracking.

Labels that are even slightly off-spec can lead to misprints, reprints or scanning issues, increasing handling time and waste.

Choosing Compatible Direct Thermal Labels

Royal Mail systems accept labels printed on compatible third-party stock, provided the material meets the functional requirements of the format.

When sourcing Royal Mail-format labels, look for:

Exact dimensions: 101.6 × 152.4 mm for correct layout.
Perforated format: For efficient handling and separation during packing.
Reliable adhesive: Secure bonding to cartons, mailers and polybags.
Consistent thermal coating: Even print density for addresses and barcodes.
Accurate die-cutting: Reduces jams, misfeeds and wasted labels.

Choosing a correctly specified label allows businesses to maintain professional despatch standards while keeping consumable costs under control.

Summary

Royal Mail shipping labels follow a clear, established format. By understanding the correct size, construction and performance requirements, businesses can confidently source compatible direct thermal labels without being tied to a single supplier.