Industry Trends

7 Common Avery Printing Mistakes I've Made (So You Don't Have To)

Real Answers to Your Avery Printing Questions

I've been handling print orders for B2B offices since 2017—and I've made more than my share of expensive errors. After wasting roughly $3,200 on reprints and delays, I started keeping a checklist. Here are the questions I wish someone had answered for me before I ordered my first batch of Avery labels.

1. Can I use Avery 5366 file folder labels for anything other than file folders?

Technically yes—but I wouldn't recommend it unless you know the adhesive and size specs. The 5366 template is designed for 2/3" x 3-7/16" labels that stick to manila folders. In 2022, I tried using them on glossy cardstock for a client's name badges. The labels peeled off within a day. Cost me $140 in replacement labels plus the embarrassment of explaining it to the client. If you need a stronger bond, look for permanent adhesive labels like Avery 5160. File folder labels use a repositionable adhesive that's fine for paper but not for coated surfaces.

2. What size are A7 envelope liners, really?

I went back and forth between buying pre-cut liners and cutting my own for weeks. Standard A7 envelopes measure 5-1/4" x 7-1/4", but the liner dimensions are smaller because you need room for the glue strip. Most suppliers recommend lining paper cut to 4-7/8" x 6-7/8" to allow a 3/8" border. I made the mistake of ordering liners at the envelope size itself—the result stuck out awkwardly and wouldn't even fit. My rule now: always verify the liner template from the envelope manufacturer, not just the envelope size.

3. Are Avery tent card templates compatible with all printers?

Not all—and this one caught me off guard in September 2023. Avery tent card templates (like the 5302 or 5305) are built for inkjet printers that can handle heavier cardstock (around 90 lb weight). I used a laser printer at my coworking space, and the heat fused the cardstock to the fuser roller. Actually, the problem wasn't the printer type—it was the substrate thickness. Laser printers need cardstock rated up to 110 lb index, but many tent card packs are 100 lb cover (about 270 gsm), which is borderline. Always check your printer's max paper weight entry in the manual. I now keep a small table of Avery product numbers and their recommended printer types.

4. What does a number on an envelope signify when I'm printing?

If I remember correctly, the number printed on an envelope (like "#10" or "A7") is a standard size designation—not an adhesive code or a quantity. For example, #10 envelopes are 4-1/8" x 9-1/2" and are the most common business envelope. But here's what tripped me: I once ordered a bulk run of "#10" envelopes thinking they all had the same window position. They didn't. The number refers to the overall dimensions, not the window placement. Always verify the window location (left, center, or right) when ordering printed envelopes. The standard for business reply envelopes is 5/8" from the left edge, but other styles vary.

5. How do I print BMO business platinum credit card info on Avery labels?

Wait—you're asking if Avery labels can be used for credit card numbers? I'd strongly recommend not printing sensitive card data on adhesive labels. That's a security risk. What you probably meant is printing return address labels for BMO business credit card statements—or maybe a label template for the credit card itself (like a temporary card sticker). For such use, Avery 5160 (1" x 2-5/8") is the standard, but I'd use a secure print environment and shred any misprints. I've had clients ask about this before. One VP tried to print 200 labels with full card numbers. We caught the error when a test label stuck to the copier glass. $0 wasted, but a close call.

6. Do I really need the official Avery template for 5366 labels?

Short answer: yes, unless you enjoy wasting money. In my first year (2017), I designed file folder labels using a generic Word table and thought I'd aligned them perfectly. Out of 500 labels, only 40 printed correctly. The rest were skewed or cut off. Avery's template (available for 5160, 5366, and hundreds of others) has pre-set margins, spacing, and column alignment that match the die-cut sheets. If you use a custom layout, you're guessing at the X-Y coordinates. Download the template from avery.com or search "Avery 5366 template" and use the .docx or .pdf version. I learned this after spending $89 on ruined labels.

7. Why does my print job look different from the screen when I use Avery tent card templates?

That's probably a color-matching issue—not the template's fault. Most office printers use CMYK, but screens display RGB. A common pitfall is using a template with Pantone swatches that convert poorly. Take this with a grain of salt: Pantone 286 C (a deep blue) converts roughly to C:100 M:66 Y:0 K:2, but on your home inkjet it might look purple-ish. I once printed a set of tent cards for a board meeting using a template that said "red." The actual result was orange. The surprise wasn't the cost—it was how awkward the client's face looked. If color is critical, ask your printer for a proof (digital or hard copy). Many online print services offer this for $10-$25. It's worth it.

Final thought: I still keep my own checklist from that $3,200 worth of mistakes. The biggest lesson: when in doubt, test a single sheet first. Most Avery products come with a free sample sheet option. Use it. You'll thank yourself.