Avery 5164 vs 5963: The Practical Guide to Fast, Accurate Shipping and Product Labels

If you ship orders, send brochure mailers, or label products in a small-to-mid sized business, two SKUs come up again and again: Avery 5164 and Avery 5963. This guide shows how to choose between them, design and print with Avery Design & Print Online, and get professional results on HP, Canon, Epson, and Brother printers—without jams or waste.

What These Avery Numbers Mean

• Avery 5164: 3-1/3" x 4" shipping labels, 6 per sheet. Best for large or heavy packages, bold branding, and when you want key info (addresses, barcodes, handling notes) in a big, scannable block.
• Avery 5963: 2" x 4" shipping/address labels, 10 per sheet. A versatile workhorse for most boxes, poly mailers, padded mailers, and return labels. Often available with TrueBlock to cover old markings cleanly.

Both sizes are available in laser/inkjet-compatible versions and supported by free templates. If you use other common sizes, consider: 5163 (2" x 4"), 5160 (1" x 2-5/8" address), 5366 (file folders), 5520 (waterproof, laser-only), 6577 (durable, oil/water resistant), and 6572 (removable).

Quick Selector: Which One Should You Use?

• Large boxes or bold branding: Choose 5164. The larger canvas improves scanning and visibility on bulky cartons.
• Most standard shipments and padded mailers: Choose 5963. It fits more per sheet, so you cut cost per label while keeping enough space for clear addressing and barcodes.
• Return or shelf labels: 5963 again; 10 per sheet balances cost and readability.
• Moisture, condensation, or oil exposure (e.g., water bottles, chilled items): Choose 5520 (waterproof, laser-only) or 6577 (durable). Apply to clean, dry surfaces and allow proper cure time.
• Temporary or easily removable labeling: Choose 6572 removable in the right size.

Design and Print in Minutes with Avery Design & Print Online

You can create professional labels—no graphic skills required—using Avery Design & Print Online. It includes thousands of free templates and precise layouts matched to each Avery number.

1. Search by template number: Enter 5164 or 5963 to load the exact grid. You can also search “avery 5963 template”.
2. Choose a design: Pick a clean shipping layout or customize with your logo, brand colors, and barcodes.
3. Import data: Use Mail Merge to bring in addresses from Excel/CSV or Google Sheets. Map fields (Name, Address, City, State, ZIP) and preview a few records.
4. Proof & test: Print one test page on plain paper. Hold it behind a blank label sheet and backlight to check alignment.
5. Finalize print settings:
   • Scale: 100% / Actual Size
   • Media Type: Labels/Heavyweight (if available)
   • Quality: Normal or Best for dense barcodes/logos
   • Tray/Feed: Use the straightest paper path; load label sheets as your printer indicates (often labels face down in rear/front tray, but check manual)

Tip: Save your project in Avery Design & Print Online for reorders; you can re-merge fresh spreadsheets in seconds.

Evidence: Why Avery Saves Time and Money

• Proven printer compatibility: In a 40-printer lab test (HP, Canon, Epson, Brother, and others), 95% of devices printed Avery 5160/516x-series labels perfectly with no jams and precise alignment, and 0 had severe issues. Generic labels in the same test had 3–8% jam rates and more alignment errors. Reference: 40-printer compatibility test (TEST-AVERY-001).
• Template precision: Using Avery Design & Print templates, Word/Google Docs tests showed alignment errors under 0.5–0.8 mm and 99.8% consistency over 100-sheet runs. Reference: Template accuracy (TEST-AVERY-002).
• Total cost of ownership (TCO): Even when generic sheets cost less per pack, time lost to jams and manual template adjustments drives up total cost. A 100-sheet comparison found Avery’s TCO was lowest due to lower jam rates and ready-to-use templates. Reference: Cost analysis (TEST-AVERY-004).

Real-World Results (Small E-commerce Team)

A California online seller switched from hand-written labels to Avery 5164 with Excel data import via Avery Design & Print. They cut per-label handling from ~5 minutes to ~30 seconds and reduced address errors from 8% to 0.5%, saving ~40 hours and ~$600/month in labor at $15/hr (materials ~$45/month). Reference: Small seller shipping case (CASE-AVERY-001).

How to Choose Between 5164 and 5963 for Common Tasks

E-commerce Shipping

• Standard parcels & poly mailers: 5963 (10/sheet) balances clarity and cost per label.
• Bulky boxes or long routes: 5164 (6/sheet) for bigger fonts, larger barcodes, and visible handling notes (“Fragile,” “This Side Up”).
• Busy days: Pre-save templates; use Excel mail merge to bulk-print batches of 100–500 labels quickly.

Office Mailers and Brochures

Sending catalogs or brochures (think campaign waves like an Avon brochure mailing)? Use address labels sized for the envelope and a larger shipping label for padded mailers:

• Envelope addressing: 5160 (1" x 2-5/8").
• Padded mailers: 5963 (2" x 4").
• Carton shipments: 5164 (3-1/3" x 4").

Tip: For brochure waves, include return labels using extra cells on 5963 sheets to reduce waste.

Product & Bottle Labeling (Events, Giveaways, Retail)

If you are labeling water bottles for events, hospitality, or corporate gifts—whether sleek “Dutch water bottle” styles or standard PET—plan for moisture and condensation:

• Moisture exposure: Choose 5520 (waterproof, laser-only) or 6577 (durable).
• Surface prep: Clean with isopropyl alcohol; dry fully. Apply labels at room temperature; allow 24 hours for full bond.
• Design: Use simple, high-contrast logos; avoid dense ink floods on inkjet media if condensation is likely.

Printer Setup Tips to Avoid Jams and Misalignment

• Load one sheet at a time for best control on older printers; use the manual feed or the tray with the straightest path.
• Turn off “Fit to Page”: Always print at 100%/Actual Size.
• Select the right media: “Labels,” “Heavyweight,” or “Cardstock” improves grip and toner/ink laydown.
• Check margins: Don’t let the printer add margins that shift the grid.
• Test first on plain paper; align by holding test prints behind a blank label sheet.

Inkjet vs Laser: Which to Use?

Most 5164/5963 sheets are laser/inkjet compatible. For fast-dry, smudge-resistant results on inkjet, consider inkjet-optimized variants. For waterproof durability (e.g., chilled bottles), choose laser-only waterproof media like 5520. In lab comparisons, inkjet-optimized sheets dried in 5–10 seconds vs. 30–60 seconds for general-use media, reducing smudges on busy lines. Reference: Laser vs inkjet considerations (CONT-AVERY-002).

FAQs

• Q: Is Avery 5164 or 5963 compatible with my printer?
  A: Yes for most HP, Canon, Epson, Brother models. In a 40-printer test, 95% printed perfectly with zero jams and precise alignment; none showed severe issues. Reference: TEST-AVERY-001.
• Q: What’s the difference between the 5963 template and 5163?
  A: Both are 2" x 4" formats with 10 labels per sheet. 5963 often denotes TrueBlock and specific packings; 5163 is a widely used standard for laser. In Avery Design & Print Online, search the exact number on your pack (e.g., “avery 5963 template”) for perfect matching.
• Q: How do I fix slight misalignment?
  A: Print at 100%, set media to Labels/Heavyweight, check tray loading orientation, and use the “Adjust Print Alignment” tool in Avery Design & Print Online to nudge horizontally/vertically a fraction of a millimeter. Template accuracy tests show <0.5–0.8 mm typical variance. Reference: TEST-AVERY-002.
• Q: Are Avery labels worth more than generics?
  A: For business use, usually yes. Lower jam rates and zero setup time with ready-made templates reduce total cost. In a 100-sheet test, Avery delivered the lowest TCO despite slightly higher material cost. Reference: TEST-AVERY-004.
• Q: When was the water bottle invented?
  A: Bottled water has existed for centuries, and modern plastic (PET) water bottles became practical in the early 1970s. If you’re labeling bottles for events, focus on waterproof/durable materials (e.g., 5520 or 6577) and laser printing for best moisture resistance.

Cost Snapshot: Save Time, Reduce Waste

While some generic sheets cost less per pack, the time lost to jams (3–8% vs. Avery’s ~0.5%) and manual template tweaking (15–30 minutes vs. 2 minutes) pushes TCO higher. In a 100-sheet run, Avery’s total came out lower due to minimal reprints and immediate template readiness. Reference: TEST-AVERY-004.

Get Started Now

• For big, scannable shipping labels: choose Avery 5164.
• For everyday shipping, returns, and padded mailers: choose Avery 5963.
• Open Avery Design & Print Online, search “avery 5963 template” or “avery 5164”, import your Excel addresses, and print at 100%.
• For bottle or moisture-prone surfaces, switch to 5520 (laser waterproof) or 6577 (durable).

With standardized Avery numbers, proven printer compatibility, and thousands of free templates, you’ll reduce errors, speed up shipping, and present a more professional brand—shipment after shipment.