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Seems its loosing calibration, try to reset to factory defult setting and it will calibrate with the labels that have at the moment. Please check settings at windows drivers (should be set up at Thermal transfere if using ribbon otherwise Direct Thermal if not using ribbon.
That issue can happen aswell if when sending a job to the printer with wrong settings, it will overrwrithe the previose settings of the printer.
you can untick the setting " use printer settings" at drivers as well.
if you need diferent driver go to www.seagulldrivers.com - this driver let you to resett printer to factury defaults. Hope it helps.Paulo.
Try this START SETTINGS PRINTER/FAXES in the pop up window go to FILE/SERVER PROPERTIES DRIVERS SELECT THE MFC5440 DRIVER AND REMOVE SELEST THE LP 2844 DRIVER AND REMOVE Now go to www.seagullscientific.com and download the Zebra driver pack, once downloaded run it and install the Zebra Lp2844 to with the USb port.
This should solve the problem, if not please come back.
The printer file is recorded in flash memory? The printer have EPL or ZPL firmware? Using ZBI may be a better solution, developed an application that stays in the printer memory and allows many uses. Roberto Martinez
This is a compatible ribbon/label combination as Zebra says. The only thing you can try is to turn up the darkness setting. The 5586 ribbon you are using requires a fairly high darkness setting ~ maybe around 25. If this still doesn't work then the best solution would be to use a Zebra card printer that prints right on the plastic card. These are made for exactly what you are trying to do. If you don't want to buy the printer then we can print them for you when you need them. I can give you my email if you want us to help.