If your Zebra printer is skipping labels, printing an extra blank label in between each print, skipping every other label, or a Zebra ZD220 is not printing at all, the cause is almost always the same: the gap sensor is out of calibration. Hold the FEED button for 5-6 seconds until the light flashes, then release to auto-calibrate. This fixes it in about 30 seconds. Here's the full step-by-step guide.
With the roll loaded and the cover closed, press and hold the FEED button for 5-6 seconds until the status light flashes, then release. The printer feeds a few labels to measure the gap and stops skipping or ejecting blanks. If it still skips, clean the sensor and check that Media Sensing is set to Gap (not Continuous).
These symptoms — one label prints then a blank one feeds, every 2nd or 3rd label is blank, or the printer spits paper without printing — all point to the sensor misreading where one label ends and the next begins. We've solved this problem hundreds of times, and it's 95% a calibration issue.
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What's the Cause of the Problem?
Zebra ZD220 uses an optical sensor to detect the gap between labels. This sensor understands where the label ends and where the new label begins.
If the printer is not calibrated, the sensor cannot read the gaps correctly. Result:
- Skipping one blank label every 2 labels
- Labels printing misaligned/shifted
- "Out of Paper" or "Media Out" error
- Starting to print from the middle of the label
This issue frequently occurs with new printers, after changing the label roll, or when switching to a different label size.
Solution 1: Calibration from the Printer (Fastest Method)
This method takes just 30 seconds:
Turn on the printer and make sure the label roll is loaded correctly.
Close the cover make sure the label passes under the sensor.
Press and hold the FEED button on the printer for 5-6 seconds.
The printer light will start flashing.
Release the button the printer will feed a few labels forward to calibrate.
When calibration is complete, the light will stay solid. ✓
During calibration, the printer may waste 3-5 labels. This is normal it's just adjusting the sensor.
Solution 2: Settings from Windows Printer Preferences
For more detailed control, you can adjust settings from Windows:
Start Settings Bluetooth and devices Printers and scanners
Find Zebra ZD220 printer and click it
Click Printing preferences button
Go to "Tools" tab
In the "Media Sensing" section, make sure "Gap" is selected
Click "Calibrate" button printer will automatically calibrate ✓
Sensor Type Settings
| Setting | When to Use |
|---|---|
| Gap (Space) | Standard labels gaps between labels |
| Black Mark | Black line on back of label |
| Continuous | Uninterrupted roll (like receipt paper) |
If your label is "gap" type but "continuous" is selected, the printer won't know where to stop and will skip. Make sure you select the correct type.
Video: Calibration via Windows Preferences
Solution 3: Auto-Calibration with LabelInn (Easiest Method)
No need to dig through Windows settings and menus. In LabelInn, calibration is fully automatic. Select your printer and click one button — done.
Select your Zebra ZD220 from the printer list
Click the "Calibrate" button
LabelInn runs automatic gap detection calibration — done in under a minute
Video: Auto-Calibration in LabelInn
Zebra ZD220 Not Printing At All? Read This First
If the ZD220 feeds labels but prints nothing, or does not respond to a print job, work through these checks before assuming a hardware fault:
- Media type mismatch: if the sensor mode is set to Continuous but you're using gap/die-cut labels, the printer never registers a label and may skip or refuse to print. Set Media Sensing to Gap and recalibrate.
- Sensor not calibrated: an uncalibrated sensor can report "media out" even with a full roll. Run the FEED-button calibration above.
- Wrong label dimensions: if your software sends a label size that doesn't match the physical media, output can be blank or shifted off the label. Match the size to your roll.
- Driver / language mismatch: the ZD220 speaks ZPL. Sending the wrong command language produces blank feeds. A driverless tool that sends native ZPL avoids this entirely — see our thermal printer software guide.
Skipping Every Other Label or Extra Blank Labels In Between
"Skipping every other label" and "printing extra blank labels in between" are two descriptions of the same root cause: the gap sensor reads two labels as one, so it feeds a whole extra label between each print. The fix is the same 30-second calibration. If the pattern persists after calibrating:
- Confirm the label gap is at least ~2 mm — sensors struggle with tiny gaps.
- Reseat the roll so the media sits flat and centered under the sensor.
- Clean the sensor window; adhesive residue is the most common repeat offender.
- Recalibrate whenever you change label brand or size — gap distance varies between rolls.
Once calibrated, a tool that sends native ZPL and auto-detects your label size keeps the sensor happy across roll changes. You can download LabelInn and calibrate the ZD220 with one click — no Windows driver dialogs.
If You Don't Want To Deal With This Problem Constantly
You need to repeat this calibration process every time you change the label roll or switch to a different label size. This is a serious time waste, especially for e-commerce sellers.
End Label Problems with LabelInn
Works with Zebra ZD220 and all ZPL-compatible printers without driver installation.
Try LabelInn for FreeFrequently Asked Questions
Where is the Zebra ZD220 calibration button?
On the front of the printer, there's a single large button visible when you close the cover - the FEED (Forward) button. Just press and hold this button for 5-6 seconds for calibration.
I calibrated but it still skips labels?
Make sure the label sensor is clean. Dust and adhesive residue accumulated inside the printer can mislead the sensor. Wipe the sensor with a soft, dry cloth.
Problem repeats when switching to a different brand label?
You need to recalibrate the printer for each different label brand/size. Label thickness and gap distance vary by brand.
I constantly get "Paper Out" error on ZD220?
This is also a symptom of calibration issue. The printer can't detect the label and thinks "paper is out." Apply the calibration steps above.
Why is my Zebra ZD220 not printing at all?
If it feeds media but prints nothing, the job is usually reaching the printer while the sensor thinks media is out, or the wrong media type is selected. Recalibrate with the FEED button and set Media Sensing to Gap (not Continuous). The ZD220 speaks ZPL, so make sure your software sends the correct command language.
Why does my Zebra printer skip every other label?
The sensor is reading two labels as one because the gap length isn't calibrated, so it feeds an extra blank label between prints. Run a FEED-button calibration, or set Media Sensing to Gap and click Calibrate in Printing Preferences.