Media Compatibility

Both Zebra and Honeywell cover their bases when it comes to printing methods and label flexibility. The ZD420/ZD421 supports both direct thermal and thermal transfer printing, with easy media swapping and a movable sensor that adapts to different label widths and gap styles. Its ribbon cartridge system is especially appealing for users who frequently switch rolls or need foolproof media changes.

The Honeywell PC45d/PC45t also supports both DT and TT configurations, though each variant is fixed at purchase. Its adjustable sensors and wide 118 mm media path accommodate a large variety of label types. Honeywell’s broader maximum width gives it a slight edge for users printing larger labels, but Zebra’s cartridge system is more user-friendly.

Print Speed and DPI

Zebra’s top print speed is 6 ips at 203 dpi and 4 ips at 300 dpi, which is perfectly adequate for most medium-volume label applications. Honeywell’s PC45 raises the bar with speeds up to 8 ips, making it the faster option when print throughput is critical. Both brands offer 203 and 300 dpi configurations, ensuring crisp barcode and text printing.

Connectivity and Communication

The ZD420/ZD421 is highly configurable: USB 2.0 and USB Host are standard, with optional serial and Ethernet modules. Wireless options include Wi-Fi 802.11ac and Bluetooth 4.1 (MFi certified), providing reliable connectivity for enterprise environments and iOS devices.

The PC45 series matches those features with USB host/device, Ethernet, Wi-Fi 802.11ac, and Bluetooth Low Energy. The key differentiator is its color touchscreen and modern embedded networking features, which make configuration and diagnostics easier directly from the printer.

Acquisition Cost

Pricing varies by configuration, but in general:

• Zebra ZD421 Direct Thermal: ~$550–$650 street price
• Honeywell PC45D: MSRP ~$1,086, street price ~$686
• Honeywell PC45T: MSRP ~$1,472, street price ~$930

Zebra typically carries the lower acquisition cost, making it more budget-friendly for small to mid-sized businesses.

Accessories and Add-Ons

Zebra offers peelers, cutters, external rewinders, and mounting kits. The accessory ecosystem is extensive and benefits from Zebra’s wide distribution network.

Honeywell’s PC45 accessory portfolio is even more comprehensive, including a cutter, peel/present mechanism, RFID module, media low sensor, and optional cellular modem. This flexibility makes it suitable for specialized or high-integration environments.

RFID Option

Zebra’s ZD420 series does not include a native RFID model—RFID support is reserved for higher-end Zebra printers like the ZD611R or ZT400 series.

Honeywell does offer an optional UHF RFID encoder for the PC45 series, giving it a clear advantage for organizations transitioning to RFID-based labeling or asset tracking.

Post-Sale Support and Serviceability

Zebra dominates the market for spare parts, repair centers, and long-term availability. Its Link-OS ecosystem provides seamless firmware updates, health checks, and centralized management across large deployments.

Honeywell’s Printer Edge platform is strong as well, offering cloud-based management and diagnostics, but Zebra’s global scale gives it a broader service advantage and more readily available replacement parts.

Warranty

Both printers carry a 2-year manufacturer warranty. Printheads and platen rollers are covered under standard consumable warranties from each brand.

Durability and Reliability

Zebra’s ZD420/ZD421 is a proven, field-tested platform with a long track record of reliability. It’s well-known for its intuitive design and consistent performance in warehouse, healthcare, and retail settings.

The Honeywell PC45 is newer but built with industrial-grade components and modern electronics. While it doesn’t yet have the same market tenure, early feedback has been positive, especially regarding its solid build and print consistency.

Software Compatibility and Integration

Zebra’s compatibility with ZPL, EPL, and Link-OS tools (including Zebra Setup Utilities and Printer Setup for iOS/Android) make it an easy fit in existing Zebra environments. It also integrates seamlessly with major ERP and labeling platforms such as BarTender and Loftware.

Honeywell counters with multi-language support (FP, DP, IPL, ZSim2, DPL) for smooth integration into mixed fleets, plus the Printer Edge cloud management suite. Both brands are well-supported in Windows, Android, and iOS environments.