OK, I have an update on this issue. My plan to use Onlinelabels.com has been scratched. I have had several communications with a representative which was eventually bumped up to the print manager, and bottom line, they could not promise me that even with in-house printing that they could get my image reasonably centered on a one inch round label. When self printing, I was getting results like this:
The far left is reasonably well centered, getting progressively worse as we move to the right. I said that I needed over 50% to be about as good as the two on the left, and most of the rest no worse than the 3rd example. I said that I would accept 5-10% as bad as the 3 on the right. They were unwilling to promise that they could do that, so I told them that I would be looking for other options.
I also decided to take a closer look at the blank label sheets themselves and I believe I discovered what the real problem is. The location on the sheet where the labels themselves are cut is not consistent. The labels can be off centered on the page by as much as a full millimeter. With my image filling up most of the label, and with print around the entire outside, that along with inconsistent printing, is not going to cut it for me.
So, my only other option while still attempting to get in well below the cost of the high quality labels from our PCF vendors is to go back to trying to find something from Avery. I've used Avery labels for years, and never had this problem of the image not printing consistently in the same place on the label. Originally I wasn't sure they made a one inch round waterproof label. Also the labels from them that I have used in the past (called Weatherproof white film) are EXTREMELY sticky. They are nearly impossible to remove, so I am hesitant to use them on a poker chip. But when I searched their site this week, I found
THIS.
If you open the "Material" drop down, you'll see a product call Surface Safe White Film for Signs. In quantity these are about double the cost of the super sticky ones, but I think that will be money well spent. Even when just applying, I may initially stick them down in the wrong spot and need to lift up and re-apply.
I'm going to order 26 sheets of this (just enough to get free shipping) at about $2 per sheet of 48 labels. I'll report back here after I've tried them out. If they work, I will get 100+ more sheets at $1.35 per sheet to finish my job. Net price (not including laser toner) will be about 6 cents per chip.