Industry Trends

Avery 5392 vs. 5164 Labels: Which One Should You Use? (And When You'll Need Two Stamps)

Avery 5392 vs. 5164 Labels: Which One Should You Use? (And When You'll Need Two Stamps)

I've been handling our company's marketing mailers and office supply orders for six years. I've personally made (and documented) at least a dozen significant labeling and mailing mistakes, totaling roughly $1,200 in wasted budget and reprints. Now I maintain our team's "pre-mailing checklist" to prevent others from repeating my errors.

Here's the thing: there's no single "best" label for every job. Picking between popular options like the Avery 5392 and 5164—or figuring out postage for what you're sending—depends entirely on your specific scenario. I used to think it was just about size, but I've learned it's about function, cost, and avoiding that sinking feeling when a batch comes back from the post office.

The Quick Scenario Guide: Which Situation Are You In?

Let's cut to the chase. Your choice boils down to three main scenarios:

Scenario A: The High-Volume Mailer. You're sending out invoices, statements, or promotional letters every week. Speed, organization, and per-unit cost are your top priorities.

Scenario B: The Occasional & Important Sender. You mail thank-you notes, contracts, or client proposals. Each piece matters, presentation is key, and you're not dealing with huge volumes.

Scenario C: The "Is This Even Mailable?" Sender. You've got something odd-shaped, thick, or heavy (like a small catalog or multiple documents). Your main worry is whether it needs extra postage.

Scenario A: Advice for The High-Volume Mailer

If you're mailing in bulk, you're probably already familiar with the classic Avery 5164 sheet. It's the workhorse: 6 labels per sheet, each measuring 3-1/3" x 4". This is your go-to for #10 business envelopes.

Here's my experience-based tip: Stick with the 5164 for pure efficiency. The conventional wisdom is to always use the integrated Avery Design & Print tool. But in practice? I've found that for simple address blocks, setting up a template in Google Docs or Word is often faster, especially if you're pulling addresses from a spreadsheet. The integration is seamless.

Where I messed up: In my first year (2018), I used a 5164 for a batch of 500 mailers, but I designed the label with a tiny font to fit a long international address. The result? About 30 were returned for illegibility. That's when I learned the lesson: Always do a physical print test on one sheet before running the whole batch. The 5164's size is generous, but cramming in too much information defeats its purpose.

Cost Note: Avery 5164 labels typically cost $12-18 for a 100-sheet pack (600 labels). Based on major online retailer quotes, January 2025. That's about 2-3 cents per label—hard to beat for volume.

Scenario B: Advice for The Occasional & Important Sender

This is where the Avery 5392 shines. It's a sheet of 2 labels, each a large 5-1/2" x 8-1/2". Basically, each label is a half-sheet of paper.

I have mixed feelings about these. On one hand, they're fantastic for making a polished impression. A contract, a certificate, a high-end promotional piece—printing directly onto this label and affixing it to a flat mailer looks incredibly professional. On the other hand, they're overkill for a standard letter and more expensive.

My "contrast insight" moment came when I compared a proposal sent on a 5392 label affixed to a sturdy mailer versus one folded into a #10 envelope. The 5392 version felt substantial, important, and was opened first. It likely influenced a client's perception. For critical communications, that can be worth the extra cost.

My Advice: Use 5392s sparingly and strategically. They're perfect for when the document itself is the label. And definitely use Avery Design & Print or a template in Canva for these—you want precise alignment for such a large, visible label.

Cost Note: Avery 5392 labels are less common and run about $15-25 for a 50-sheet pack (100 labels). That's 15-25 cents per label. Verify current pricing, but it's a premium option.

Scenario C: Navigating Postage & The "Two Stamp" Question

This was my most expensive lesson. You've printed your labels (5164, 5392, or something else), stuck them on your mailer, and now you're at the post box. One stamp or two?

The rule isn't about labels; it's about your final envelope or package. According to USPS (usps.com), a First-Class Mail 1-ounce letter costs $0.73 as of January 2025. Here's the decision tree I created after a $450 mistake on a catalog mailing:

You likely need TWO stamps (or a $1.55 Forever Stamp) if your mailer is:

• Over 1 oz in weight: A standard #10 envelope with 4-5 sheets of paper often crosses this threshold. Get a kitchen scale.
• Over 1/4" thick: Think padded envelopes, rigid photo mailers, or folded brochures with multiple pages.
• Non-rectangular or rigid: Odd shapes cost more to process.

So glad I bought that $20 kitchen scale for the office. Almost guessed on weight for a 300-piece holiday card mailing, which would have meant all of them arriving late with postage due—a customer service nightmare.

Pro Tip: If you're using a large, heavy label like the 5392 on a thick cardstock mailer, you are almost certainly in "two stamp" territory. Weigh one completed piece.

How to Decide: Your Action Plan

Still unsure? Walk through this:

1. What's the volume? High, repetitive mailing = Avery 5164. Occasional, special piece = consider Avery 5392.
2. What's the priority? Cost & efficiency = 5164. Impact & presentation = 5392.
3. What are you mailing? Standard letter in a #10 envelope = 5164. Flat, important document = 5392.
4. Check the final package. Before sealing, WEIGH IT and MEASURE ITS THICKNESS. Compare to USPS rules. This 2-minute check has saved us hundreds.

Part of me wants to say the 5164 is the only label anyone needs. Another part knows that having a box of 5392s in the supply closet has saved the day for last-minute, high-stakes mailings. I compromise by keeping both on hand, but using the 5164 for 95% of our work.

The vendor who acknowledges that their product (like the 5392) isn't for every job actually earns more trust for their core products. It shows they understand real-world use, not just a sales sheet. Choose the tool that fits your actual task, not the one that seems most versatile. And for heaven's sake, weigh your mail.

Pricing references based on publicly listed prices from major online retailers, January 2025. Verify current rates. USPS pricing and rules are subject to change; verify current regulations at usps.com.