Avery Printing FAQ: Save Money on Labels, Templates & Mailing

If you're managing a printing budget—whether for a small office, a growing brand, or your own side hustle—you've probably asked yourself: How do I get professional labels without blowing my budget? This FAQ answers the questions I hear most often from fellow procurement folks. I’ve been tracking our label spending for years (over $18,000 cumulatively since 2021), and these are the real-world answers I wish someone had given me.

1. What is Avery printing, and can it really save me money?

Avery printing refers to using Avery-branded label sheets, cards, and their free online templates to print your own labels, business cards, name badges, and more. From the outside, it looks like you're just buying paper. The reality is that Avery's pre-designed templates eliminate design fees, reduce waste from misalignment, and let you print exactly what you need—no minimum orders. In my experience, switching from custom-printed labels to Avery print-label sheets cut our per-label cost by 62% (based on our Q2 2023 spend analysis). Plus, you don't pay rush fees when you can print on demand.

2. How do I use an Avery 5567 template?

The Avery 5567 is a popular template for return address labels (½" x 1¾", 20 per sheet). Here's the quick workflow: go to avery.com/templates, search “5567”, choose your design or start blank, then type your addresses. You can open it directly in Word or Google Docs. I used to think customizing a template would take forever—until I timed it: 4 minutes for a full sheet. Compare that to the $35 our old design agency charged for “address label setup” (note to self: why did we tolerate that for so long?). Pro tip: always do a test print on plain paper first (ugh, learned that after wasting a whole sheet once).

3. Can I use Avery templates to create a baby wearing brochure?

Yes, and it’s a clever way to save. A baby wearing brochure usually requires a tri-fold design with clear product photos and safety instructions. Avery offers brochure templates (e.g., 5305 for tri-fold) that you can customize with your own content. I helped a client in the baby products industry do exactly this. They assumed they needed a graphic designer ($400 quote). Instead, we used an Avery brochure template, printed on their color laser printer, and the total cost was under $25 for 200 copies (paper + ink). The key is to choose a template with the correct fold guides and bleed margins. (I really should blog about this case study—it’s a perfect example of industry evolution: 5 years ago, small businesses had to order 1,000 brochures minimum. Now, print-on-demand with Avery makes small runs economical.)

4. How do I make custom labels for a duffel bag with water bottle pocket?

For a duffel bag that includes a water bottle pocket, you might want labels for branding, care instructions, or size tags. Avery offers printable fabric labels (like the 8395) that can be ironed on, or adhesive vinyl labels (like the 77177) for waterproof durability. Here’s what I learned when we labeled 300 bags for a sports gear company: total cost per label was $0.18 (compared to $0.85 from an external decorator). People assume that label material determines price, but the real hidden cost is setup time. Custom orders often include $50–$100 setup fees that you never see in the per-unit price. With Avery, you design once, save the template, and reprint as needed. (Thankfully, we found this before committing to a custom order.)

5. How to mail an envelope properly with Avery address labels?

Mailing an envelope seems simple, but I’ve seen too many packages returned due to improper addressing. Use a standard address label like the Avery 5160 (1" x 2⅝", 30 per sheet). Position the label in the center of the envelope, leaving at least ⅝" from the top and bottom edges. According to USPS guidelines (effective January 2025), the address should be in the center of the envelope’s longest side, with a clear zone of at least ½" on all sides. For large envelopes or bubble mailers, use a larger label (e.g., 8163). I still kick myself for not knowing that USPS charges a surcharge for non-machinable envelopes. We once mailed 500 invitations with non-standard dimensions—cost us an extra $120 in surcharges. Now I always check the USPS pricing guide before printing. (Note to self: update our mailing checklist.)

6. Why should I use Avery templates instead of designing from scratch?

Designing labels from scratch in Word or Canva might seem more flexible, but every mismatch in margins or alignment costs time and material. In Q1 2024, I compared two identical label projects: one using an Avery print-label template (free) and one hand-built. The hand-built version required 3 test prints (wasted sheets) and 45 minutes of tweaking. The Avery template worked on the first try. Over a year, those small wastes add up—probably $200–$300 in wasted label stock and ink alone. (If you ask me, the template is the cheapest insurance you can buy.)

7. What hidden costs should I watch out for when ordering custom labels?

People assume the lowest quote per label is the most cost-effective. What they don't see is the hidden fees: artwork setup ($25–$50), die-cutting ($75–$150), shipping minimums, and reorder minimums that force you to stock extra inventory. One vendor quoted us $0.12 per label but charged $100 for setup—making a 500-label first order cost $0.32 per label. I’ve been tracking 8 vendors over 3 years (our procurement system has 42 orders logged). The pattern is clear: always request a total-cost breakdown before committing. Avery’s approach—buy blank sheets, use free templates—eliminates almost all of those hidden costs. The trade-off? You handle printing and cutting yourself. But for most small to mid-size needs, that trade-off saves 30–50%.

8. How has label printing changed in recent years?

Industry evolution is real. In 2020, many companies still used dedicated label printers (Dymo, Brother) because the online template ecosystem was immature. Now, Avery’s Design & Print online tool rivals professional software. Laser/inkjet quality has improved dramatically—as of 2025, a $200 color printer can produce labels that look almost like offset. The fundamentals (use a template, test print, check adhesive quality) haven't changed, but the execution has transformed. If you’re still using a 5-year-old workflow, you might be leaving money on the table. I’d argue that the biggest change is accessibility: any business, any budget, can now produce labels that look custom without paying custom prices.