Avery 5160 Printing Tips & Alignment Guide

Last updated: February 2026 • 6 min read

Printing Avery 5160 labels should be straightforward, but alignment issues are frustratingly common. This guide covers the most frequent problems and how to fix them, whether you're printing from UrbanKit Studio's CSV to Labels tool or any other source.

The Golden Rule: Always Test Print First

Before wasting expensive label stock, always print a test page on plain paper. Here's the technique:

1. Print your label PDF on regular paper
2. Hold the printed sheet up to a window with an unused label sheet behind it
3. Check if the printed text aligns within the label boundaries
4. If it's off, adjust your settings and test again

Critical Printer Settings

1. Paper Size: Letter (8.5" × 11")

Make sure your printer is set to US Letter, not A4 or any other size. This is the most common cause of alignment issues.

2. Scaling: None (100% or "Actual Size")

This is the #1 cause of misaligned labels. Look for these settings in your print dialog:

• Adobe Reader: "Actual Size" (not "Fit" or "Shrink")
• Chrome: "None" under Scale
• Preview (Mac): "100%" or uncheck "Scale to Fit"
• Windows: "Actual Size" or "100%"

3. Margins: Default or None

Don't set custom margins in the print dialog. The PDF already has the correct margins built in.

4. Media Type: Labels (if available)

Some printers have a "Labels" media type that adjusts feed speed and heat. This can prevent jams and smearing.

Troubleshooting Alignment Issues

Labels Shift Down the Page

Each row is progressively lower than it should be. This usually means:

• The PDF is being scaled down (check your print scaling setting)
• Wrong paper size selected
• Printer is adding extra margins

Labels Shift to One Side

Text drifts left or right across columns:

• Check that you're printing on the correct side of the paper
• Some printers have a slight horizontal offset—you may need to adjust in the PDF before printing

First Row OK, Others Off

Classic sign of scaling issues. Even 99% scaling will cause noticeable problems by the last row.

Random Misalignment

If alignment varies between prints:

• Check paper feed—are sheets going in straight?
• Try feeding one sheet at a time
• Clean printer rollers
• Use genuine Avery labels (some off-brand sheets have slightly different dimensions)

Printer-Specific Tips

HP Printers

• Use the "HP Smart" app or built-in Windows driver (not the "HP Easy Start" driver)
• Set media type to "Labels" if available
• Disable "HP Real Life Technologies" which can resize content

Brother Printers

• Set paper type to "Thick Paper" or "Labels"
• Use the rear (straight-through) paper path if available

Laser vs. Inkjet

• Laser: Use laser-compatible labels (Avery 5160 is laser-safe). Don't use inkjet labels in a laser printer—they can melt.
• Inkjet: Use Avery 8160 (inkjet version) for best print quality. 5160 will work but colors may not be as vibrant.

Loading Labels Correctly

• Load labels print-side up in most printers (check your manual)
• Don't overload the tray—10 sheets max to prevent jams
• Fan the sheets before loading to prevent sticking
• Use the manual feed tray for best results

When Labels Keep Jamming

1. Feed one sheet at a time using the manual/bypass tray
2. Check label edges—if labels are peeling up at corners, they can catch inside the printer
3. Don't reuse sheets—once labels are removed, the exposed adhesive causes jams
4. Store labels flat—curled sheets jam more easily

Partial Sheets: The Waste Problem

If you have 47 addresses, you'll use 2 full sheets (60 labels), leaving 13 blank labels. Options:

• Save partial sheets for small batches
• Plan batch sizes to use full sheets
• Accept some waste as more cost-effective than manual workarounds

Related Resources

• Deduplicating Mailing Lists: LLCs, Trusts, and Same-Owner Parcels
• Public Notice Radius Requirements: What Varies by Jurisdiction
• Radius Notice Mailing List Generator