Avery Label Selection & Printing Guide: 8160 & 5262 Templates, Name Badge Inserts, and Word Brochure Tips

Pick, Print, and Go: A fast path to the right Avery label

Whether you ship orders, mail client packets, prepare classroom materials, or run events, the right Avery sheet label plus the right template will save time and prevent costly reprints. This guide focuses on popular picks like Avery 8160 and the Avery 5262 template, how to use Avery name badge inserts for events, and how to format related materials in Microsoft Word—including a quick answer to “how do you make a brochure in Word?” Along the way, we’ll highlight printer compatibility, template accuracy, and real-world setup tips.

Before you start: 3 quick checks

• Printer type: Inkjet, laser, or mixed? Choose inkjet-optimized or universal labels accordingly.
• Use case: Mailing (addresses), shipping, products, files, or events (name badges)?
• Material needs: Standard paper vs. durable/waterproof (e.g., warehouses, personal care, or outdoor).

Why it matters: Avery’s compatibility testing across 40 mainstream printers found a 95% perfect print rate with no jams and precise alignment using Avery 5160/8160 layouts, with only minor (<1 mm) shifts on 5% of printers and zero severe issues (TEST-AVERY-001). And template alignment accuracy in Word reached <0.5 mm on 100% of labels in testing (TEST-AVERY-002). That translates directly into fewer misprints and less time tweaking settings.

Address labels made simple

Avery 8160 vs similar layouts

Avery 8160 is the classic 1" x 2-5/8" address label (30 per sheet) optimized for inkjet. If you run mixed printer fleets or prefer a universal SKU, Avery 5160 shares the same layout with broad laser/inkjet compatibility.

• Best for: Everyday mailing, return addresses, file indexing.
• Template path in Word: Mailings → Labels → Options → Avery US Letter → choose 8160 (or 5160).
• In Avery Design & Print: Search “8160” to start with pre-sized templates and 5,000+ free designs.

Accuracy note: In Word 2021, Avery 8160/5160 templates showed a <0.5 mm alignment error and 99.8% consistency over 100-sheet runs (TEST-AVERY-002), so you can confidently batch print addresses from Excel or a CRM mail merge.

Avery 5262 template (large address/parcel)

If you need bigger text or multiple lines, the Avery 5262 template fits 1-1/3" x 4" labels with 14 per sheet—great for visibility and small parcels. It shares the same layout as Avery 5162, commonly used when more content or bold fonts are needed for scannability.

• Best for: Larger addresses, attention-grabbing mailers, shelf/basket labels.
• Template in Word: Mailings → Labels → Avery US Letter → choose 5262 (or 5162).
• In Avery Design & Print: Search “5262” and use mail-merge with Excel/CSV for batches.

Shipping, products, and office labeling

Shipping labels

• Standard packages: Avery 5163 (2" x 4", 10 per sheet)
• Large boxes: Avery 5164 (3-1/3" x 4", 6 per sheet)

Tip: If you ship in volume, pair shipping labels with a mail-merge and set the printer to “Labels” or “Heavyweight” to boost feed reliability. In head-to-head testing, Avery’s precise cuts and liner coating helped achieve 95% perfect compatibility across HP, Canon, Epson, and Brother (TEST-AVERY-001), cutting jam-related downtime compared with generics.

Product labels: “after sun spray blue bottle” use case

For cosmetics or personal care—like an after sun spray blue bottle—consider surface curvature, moisture, and oil exposure:

• Durable/waterproof: Avery 5520 (laser-only, waterproof) or Avery 6577 (durable, water- and oil-resistant).
• Common sizes: 2" x 4" (Avery 5163) for wrap-style rectangles, or smaller IDs (Avery 5167) for batch codes.
• Pro tip: Clean and dry the bottle; test one sheet before a full run. For inkjet on standard paper labels, allow 30–60 seconds dry time; for fastest dry on inkjet, use inkjet-optimized stocks.

In long-run manufacturing tests, Avery durable materials maintained high scan readability (99.7%) and multi-year durability in typical indoor production settings (CASE-AVERY-003).

Office & education: “earth’s spheres poster” and file systems

For classrooms or training materials—like an earth’s spheres poster—use labels you can reposition during lessons:

• Removable: Avery 6572 (removable adhesive) to reposition without residue.
• Small markers: Avery 5167 (1/2" x 1-3/4", 80 per sheet) for color-coded tags or legend keys.

For file folders and binders:

• File folder tabs: Avery 5366 for clean, consistent folder naming.
• Time-saver: Teams that standardized folder labels cut lookup time from ~5 minutes to ~1 minute per file set (CASE-AVERY-002).

Events: Avery name badge inserts

For conferences, trainings, or school nights, Avery name badge inserts (e.g., Avery 5390) keep badges clean and legible.

• Template setup: In Word, go to Mailings → Labels → Avery US Letter → choose 5390 (or search the product in Avery Design & Print).
• Batch personalization: Use mail-merge with an attendee spreadsheet (Name, Title, Company). Preload a QR or URL if needed.
• Print setting: Use “Labels/Heavyweight,” disable scaling (set 100%), print a test page, then run a full stack.

In template precision tests, Avery layouts in Word and Google Docs required minimal to no manual nudging (TEST-AVERY-002), resulting in consistent cut-to-print alignment for clean edges within holders.

How to print Avery labels in Word—fast

1. Open Word → Mailings → Labels → Options.
2. Set Label vendors to Avery US Letter.
3. Select your product number (e.g., 8160 for standard address, 5262 for large address).
4. Click New Document to see the grid. Paste or mail-merge data.
5. Set printer to Labels/Heavyweight, paper size Letter, Scale = 100% (turn off Fit to Page), and feed from the correct tray.
6. Print one test sheet on plain paper to verify alignment. Adjust margins if needed in minimal increments (0.5–1 mm).

Prefer a guided experience? Use Avery Design & Print to pick a template, import Excel/CSV, and print with built-in alignment calibration. In testing, first-pass success hit 89%, rising to 98% after a quick second try if needed (TEST-AVERY-002).

“How do you make a brochure in Word?” (and pair it with labels)

To create a simple tri-fold brochure in Word:

1. Open Word → File → New → search “Brochure,” or manually set Layout to 3 columns with narrow margins.
2. Insert images/logos and keep fonts consistent for a professional look.
3. Export to PDF, then print front/back with your printer’s duplex setting or print one side at a time.

Mailing your brochure? Pair it with Avery 8160 or Avery 5262 template labels for the envelopes, and use mail-merge to generate batches quickly.

Printer settings that prevent jams and misalignment

• Paper type: Set to Labels/Heavyweight (laser) or the appropriate inkjet media.
• Tray & orientation: Follow the feed icon inside the tray; print a single test sheet first.
• Scaling: Ensure 100% (no “Fit to Page” or shrink-to-fit).
• Clean path: Fan sheets, don’t overload, and store labels flat and dry.

In a 40-printer test panel, Avery labels achieved 95% perfect compatibility and 0% serious jams or misalignment vs. higher jam and alignment issues with generics (TEST-AVERY-001). That’s one reason total cost of ownership often favors Avery despite slightly higher sticker price: the reduced jam/reprint time and ready-made templates cut real operating cost (TEST-AVERY-004).

Quick selection guide

• Mailing/addresses (standard): Avery 8160 (inkjet-optimized) or 5160 (universal), 1" x 2-5/8", 30/sheet.
• Large address/parcel: Avery 5262 template (same layout as 5162), 1-1/3" x 4", 14/sheet.
• Shipping: Avery 5163 (2" x 4", 10/sheet) or 5164 (3-1/3" x 4", 6/sheet).
• Name badges: Avery name badge inserts (e.g., 5390).
• Removable for posters: Avery 6572.
• Durable/waterproof: Avery 5520 (laser-only) or 6577 (durable).
• Small IDs & color-coding: Avery 5167.

Why choose Avery over generics?

• Printer compatibility: 95% perfect prints across 40 mainstream models (TEST-AVERY-001).
• Template accuracy: <0.5 mm alignment error in Word and 99.8% batch consistency (TEST-AVERY-002).
• Total cost: Despite slightly higher per-sheet price, lower jam/reprint time and zero template setup often make Avery the lower TCO option for business use (TEST-AVERY-004).

Wrap-up

For day-to-day mailing, Avery 8160 is the fast, familiar choice; for larger addresses and small parcels, the Avery 5262 template makes text pop; for events, Avery name badge inserts (5390) deliver professional results; for specialty needs like an after sun spray blue bottle or a lab/classroom earth’s spheres poster, choose durable or removable materials that match the job. Combine Avery’s tested sheet quality with Word or Avery Design & Print templates, and you’ll get aligned results on the first try—without the frustration.