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Avery 5160 Printing Tips & Alignment Guide

By · Last updated April 26, 2026 · 6 min read

Printing Avery 5160 labels should be straightforward, but alignment issues are 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 another source.

Avery 5160 Specifications

  • Label size: 1" × 2⅝" (25.4mm × 66.7mm)
  • Labels per sheet: 30 (3 columns × 10 rows)
  • Sheet size: 8.5" × 11" (Letter)
  • Top margin: 0.5"
  • Side margins: 0.1875" (3/16")
  • Vertical gap: 0" (labels touch)
  • Horizontal gap: 0.125" (1/8")
Avery 5160 sheet layout: 3 columns by 10 rows of labels on a US Letter sheet A scale diagram of the Avery 5160 label sheet showing 30 labels arranged in 3 columns and 10 rows, with 0.5 inch top and bottom margins, 0.1875 inch side margins, and 0.125 inch horizontal gaps between columns. 0.5" top margin 0.1875" side 2⅝" 1" 8.5" × 11" Letter — 30 labels (3 × 10)
Avery 5160 sheet layout: 30 labels per sheet at scale.

The Golden Rule: Always Test Print First

Before wasting expensive label stock, print a test page on plain paper. 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 whether the printed text falls inside the label boundaries
  4. If it's off, adjust your settings and test again
Pro tip: Keep one "test sheet" of labels you've already printed on. Hold your plain-paper test print against it to check alignment without using fresh labels.

Critical Printer Settings

1. Paper Size: Letter (8.5" × 11")

Set your printer 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")

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%"
Common mistake: "Fit to Page" or "Shrink to Fit" scales your labels down a little, causing progressive misalignment across the sheet.

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. It can prevent jams and smearing.

Troubleshooting Alignment Issues

Labels Shift Down the Page

Each row is progressively lower than it should be. 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 horizontal offset; you may need to adjust the PDF before printing

First Row OK, Others Off

Classic sign of scaling issues. Even 99% scaling causes visible problems by the last row.

Random Misalignment

If alignment varies between prints:

  • Check paper feed; are sheets going in straight?
  • Feed one sheet at a time
  • Clean printer rollers
  • Use genuine Avery labels (some off-brand sheets have 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"; it 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 printer: Use Avery 5160, the laser SKU. Don't use 8160 (inkjet labels) in a laser printer; the heated fuser can melt the inkjet face.
  • Inkjet printer: Use Avery 8160, the inkjet SKU with the same dimensions as 5160 but a face engineered for wet ink. Don't use 5160 in an inkjet; the laser-rated face causes pooling and smearing.

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; cheaper than manual workarounds

Ready to print your mailing labels?

Open the CSV to Labels Tool →

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