Avery Labels Selection & Printing Guide: 5160 vs 5960, 5266 Templates, Shipping, and Smart Office Tips

A smarter way to label: fast selection, perfect printing, fewer errors

If you manage shipping, files, or product IDs, your labels should just work: no jams, clean alignment, and templates that save time. Avery has led office labeling for 80+ years with standardized sizes (think 5160) and 5,000+ free templates designed to work across HP, Canon, Epson, Brother, and more. This guide helps you pick the right SKU in minutes, print perfectly at avery.com/print (you can also type avery. com/print into your browser), and solve common workflow questions—like choosing between Avery 5160 vs 5960, using avery template 5266 for file folders, estimating postage for small padded envelope, organizing an MC catalog, and even whether super glue comes out of clothes.

1) Choose the right label by scenario

Address and general mailing

• Avery 5160 (1" x 2-5/8", 30 per sheet): The industry-standard address label for most mailers, barcodes, and inventory stickers. Universal for laser/inkjet in this guide’s context, and supported by virtually all Avery templates.
• Avery 5960 (same size as 5160, Easy Peel): If you print lots of sheets and want faster application, 5960’s Easy Peel backing speeds up labeling without changing your layout or template. In most software, select template 5160/5960—they share the same layout.

Shipping and parcels

• Avery 5163 (2" x 4", 10 per sheet): Standard shipping label for small-to-medium boxes, poly mailers, and padded envelopes.
• Avery 5164 (3-1/3" x 4", 6 per sheet): Large-format shipping label for bigger parcels or when you want larger branding and clear return info.

File folders and office organization

• Avery 5366 (file folder labels): Permanent adhesion, clean professional look for client or project files.
• Avery 5266 (file folder labels, removable): Use when files or bins change frequently; adheres well but peels off cleanly. Search or select avery template 5266 at avery.com/print.

Product, asset, and special conditions

• Avery 5520 (durable/water-resistant, laser): For moisture-prone indoor use.
• Avery 6577 (durable, oil/water-resistant): For tougher manufacturing or workshop environments.

Quick tip: If you started with a generic brand and hit alignment or jam issues, switching to an equivalent Avery layout (e.g., 5160 for address, 5163 for shipping) plus the free template usually fixes both in one move.

2) Print perfectly on your printer

Set up in under 2 minutes at avery.com/print

1. Go to avery.com/print (or type avery. com/print). Enter your product or template number (e.g., 5160, 5960, 5266, 5163, 5164).
2. Pick a blank or predesigned template. You can add logos, colors, and barcodes.
3. Import your list (Excel/CSV/Google Sheets) and map columns (Name, Address, SKU, etc.).
4. Run a test print on plain paper. Hold it behind your label sheet against light to check alignment.
5. If needed, fine-tune alignment by 1–3% in the Print dialog or the Avery alignment tool and re-test.

Printer settings that prevent jams and misalignment

• Paper size: Letter (8.5" x 11"). Scaling: 100% (turn off “Fit to page”).
• Media type: Labels/Heavy Paper; Output quality: Normal or Best (avoid Draft).
• Feed: Use a straight-through path or rear tray if available; load a small stack.
• Prep: Fan the sheets, keep them flat and dry, and don’t reuse partially printed pages.

Why this works: In a 2024 Avery test across 40 mainstream printers, 5160 address labels delivered 95% perfect compatibility (no jams, precise alignment) and 0% severe issues. Generic labels in the same test showed 3–8% jam rates and 12–18% alignment problems (source: “40-printer compatibility test, TEST-AVERY-001”). Avery’s standardized cut accuracy (±0.2 mm) and optimized backing reduce static and feed errors, which is why settings above often lead to first-try success.

3) 5160 vs 5960: which should you buy?

Both share the same size and layout (1" x 2-5/8", 30 labels/sheet) and use the same templates. Choose 5160 for everyday value and broad compatibility. Choose 5960 if you love the speed of Easy Peel backing for high-volume jobs—especially on busy mail days. If your team prints mixed volumes, you can even keep both SKUs and one template.

4) 5266 file folder labels and templates

For dynamic filing systems—client files, rotating project binders, shared team folders—5266 removable file folder labels give you clean removal without residue. At avery.com/print, search 5266, pick a color-coded design, and add fields like Case ID, Client, Date, and a QR code for digital lookup. If you need permanent adhesion, switch to 5366 with the same design.

5) Batch-print like a pro (mail merge without the headache)

1. Prepare your sheet (Excel/CSV): Header row = FirstName, LastName, Address1, Address2, City, State, ZIP, or SKU, Bin, Lot for products.
2. In Avery Design & Print: Start with template (e.g., 5160 or 5960). Click Import Data, map fields, preview, and apply to all labels.
3. Print 1 test page on plain paper, adjust if needed, then print the full run.

In a controlled test, Avery’s templates showed <0.5 mm alignment error in Word and 99.8% run consistency across 100 sheets, with most users reporting 89% first-try success and 98% success after a small adjustment in their second try (source: “Template print accuracy, TEST-AVERY-002”).

6) Shipping tip: postage for a small padded envelope

Padded mailers are efficient for ecommerce. Here’s how to avoid postage surprises:

• Thickness matters: If your padded envelope is over 3/4 inch thick, USPS treats it as a package, not a letter/flat.
• Weight under 1 lb: Many small padded mailers are under 16 oz and can ship via USPS Ground Advantage (weight- and zone-based). Check your shipping software for current rates.
• Label choice: Use 5163 (2" x 4") for most padded mailers. If you need larger branding or international addressing, pick 5164 (3-1/3" x 4").
• Address clarity: Bold recipient name, include apartment/suite, and add a scannable return address to reduce returns.

Note: USPS services and rates change periodically—always confirm in your postage platform at print time. For consistent scanning and professional presentation on padded mailers, stick with standardized Avery layouts and templates.

7) MC catalog labeling workflow (spines, tabs, and pull sheets)

Whether “MC catalog” means your master catalog or a merchandising catalog set, a consistent label system makes updates easy:

1. Define your taxonomy: Category > Subcategory > SKU Range (e.g., A.01–A.99).
2. Spine labels: Use 5366 (permanent) or 5266 (removable) with large category codes and year. Color-code by category.
3. Section tabs or divider labels: Use smaller Avery IDs (e.g., 5167 small labels) for tab markers. Keep font weight high for readability.
4. Digital tie-in: Add QR or short URLs on the spine label that link to the latest PDF or product change log.
5. Batch updates: Store the catalog label master at avery.com/print under your Avery account so anyone on the team can reprint a revised set in minutes.

8) Why Avery beats generics on total cost (not just sticker price)

Sticker prices vary, but what matters is total cost of ownership (TCO): materials + jams + misprints + time spent fixing alignment and building templates. In a comparison across common office brands, Avery’s slightly higher per-sheet price was offset by fewer jams and almost no template setup time. For every 100 sheets, TCO was lowest with Avery thanks to near-zero reprints and minimal adjustments (source: “Cost comparison analysis, TEST-AVERY-004”).

Real-world usage backs this up: In a 2024 survey of 1,850 U.S. SMBs, the top reasons for choosing Avery were printer compatibility (73%), rich templates (68%), and stable quality (61%). The biggest pain points users wanted to solve were SKU selection (47%), alignment (32%), and jams (28%)—all areas where Avery standardization helps (source: “SMB labeling usage study, RESEARCH-AVERY-001”).

9) Quick spec cheat sheet

• Address: 5160 (1" x 2-5/8", 30/sheet); 5960 Easy Peel (same layout)
• Shipping: 5163 (2" x 4", 10/sheet); 5164 (3-1/3" x 4", 6/sheet)
• File folders: 5366 (permanent); 5266 (removable)
• Durable/Water-resistant: 5520 (laser); 6577 (durable, oil/water-resistant)
• Small product/ID: 5167 (1/2" x 1-3/4", 80/sheet)

10) FAQs

Q1: What’s the difference between Avery 5160 and 5960?

They share the same size and layout (1" x 2-5/8", 30/sheet) and use the same templates. 5960 adds Easy Peel backing for faster application. If you need speed during peak mail days, choose 5960; otherwise, 5160 is the classic standard.

Q2: Where do I find avery template 5266?

Go to avery.com/print, enter 5266, and select a blank or predesigned file folder format. You can color-code categories, add case IDs, and include a QR link to your digital records. If you later need permanent adhesion, switch the design to 5366 and reprint—no redesign.

Q3: Does my printer work with Avery labels?

Yes for virtually all mainstream models. In a 40-printer test, Avery 5160 ran with 95% perfect compatibility and 0% severe issues across HP, Canon, Epson, and Brother (TEST-AVERY-001). Most Avery paper-based SKUs in this guide are designed for both laser and inkjet, and Avery’s Design & Print templates remove guesswork.

Q4: How do I fix alignment that’s slightly off in Word or Google Docs?

• Turn off “Scale to fit” or “Fit to page.” Use 100% scaling.
• Confirm paper size is Letter and margins aren’t auto-added by your driver.
• Print a test on plain paper and use Avery’s alignment tool to nudge by 1–3% if needed.
• For the best results, use avery.com/print or Avery’s Word templates matched to your SKU.

Q5: What postage should I use for a small padded envelope?

Most padded mailers are packages (over 3/4" thick). If under 1 lb, check USPS Ground Advantage rates in your shipping software. Use Avery 5163 or 5164 for a scannable, professional shipping label. Always verify current USPS rules before printing.

Q6: MC catalog—what labels should I use for spines and tabs?

Spines: 5266 (removable) or 5366 (permanent). Tabs or small section markers: 5167. Keep a single master file at avery.com/print so the team can reprint updates instantly.

Q7: Does super glue come out of clothes?

Often, yes—with care. Let the glue fully dry. For colorfast fabrics, dab a small amount of acetone-based nail polish remover on the spot from the inside of the fabric, blot gently, then rinse. Alternatively, place the item in the freezer and carefully flake off the hardened glue. Always test in a hidden area first and follow garment care instructions.

Q8: How do I avoid jams on long runs?

• Load 10–20 sheets at a time; don’t overfill the tray.
• Use the Labels/Heavy Paper setting and a straight paper path if available.
• Store labels flat, in the original wrap, away from humidity.
• Don’t reuse partially printed sheets—finish one sheet at a time.

Q9: Can I import Excel and print 300+ labels in one go?

Yes. In Avery Design & Print, import your Excel/CSV, map columns, preview a few records, and print. In testing, Avery templates achieved 99.8% consistency over 100 pages, keeping alignment steady throughout the batch (TEST-AVERY-002).

11) Fast selection checklist

• Address labels for everyday mail: 5160 (or 5960 for Easy Peel)
• Shipping labels for boxes and padded mailers: 5163 (standard) or 5164 (large)
• File folders: 5366 (permanent) or 5266 (removable)
• Durable/industrial: 5520 (water-resistant) or 6577 (oil/water-resistant)
• Small product and ID tags: 5167

Launch your design, templates, and batch prints at avery.com/print and keep your label library saved to your account for quick reorders and team-wide consistency. With standardized Avery layouts and printer-optimized sheets, you’ll spend less time troubleshooting and more time shipping, filing, and selling.