Evri shipping labels are generated in a format that fits a standard 100 × 150mm thermal printer, but getting them to print cleanly at the right size trips up plenty of sellers, especially those switching from Royal Mail. The barcode is what Evri's network scans, so a mis-sized or fuzzy label means failed scans and delayed parcels.
Set the label size to 100 × 150mm
The first and most important setting is the paper size. Your printer driver and print dialog should both be set to 100 × 150mm, or 4x6 inches, before you print anything. If the driver is set to A4 or Letter, the label will be scaled or clipped, and the barcode may be unreadable even if it looks fine on screen.
Download the label as a PDF and print at 100%
When you generate an Evri label, download it rather than printing straight from the browser. Open the PDF and print at 100% scale with 'fit to page' turned off, because any scaling that shrinks the barcode can make it fail to scan. This is the single most common fix for Evri labels that print slightly too small.
Use the right driver, not a generic one
Thermal printers need their specific driver installed and selected, not a generic or AirPrint fallback. If you're on a Zebra, Citizen, TSC or Brother printer, install the manufacturer's driver and confirm it's selected in the print queue. Our driver installation guide covers this for Zebra specifically, but the principle applies to all brands.
Check the darkness setting
Thermal printers have a darkness or density setting that controls how dark the print is. Too light and the barcode lines are faint, too dark and the bars blur together. Either extreme causes scan failures. If Evri labels look washed out or smudged, adjust the darkness before blaming the label file.
Orientation and margins
Evri labels are usually portrait in a 100 × 150mm frame, so make sure the page orientation and margins are set correctly in the print dialog. A mismatch that rotates or offsets the label can clip the barcode or the address, and a clipped address is a parcel that can't be delivered.
Test before a big batch
Before printing a day's worth of Evri labels, print one and scan the barcode with a phone to confirm it reads correctly. A quick scan test catches sizing and darkness problems before they affect real parcels, and it's the same habit worth building for DPD and other carriers too.
Switch between Evri and Royal Mail labels
Because both Evri and Royal Mail use a 100 × 150mm format, you can print both from the same 4x6 printer and the same roll of labels, you just change the source of the PDF and keep the print settings consistent. That interchangeability is one reason a 4x6 direct thermal printer is the standard tool for multi-carrier dispatch, covered in our courier label requirements guide.
Frequently asked questions
Why is my Evri label printing too small? The paper size or scale is usually set wrong. Set the driver to 100 × 150mm and print the PDF at 100% with 'fit to page' off.
What darkness setting should I use for Evri labels? Start at the printer's default and adjust until the barcode is dark and crisp without the bars blurring. Scan-test a label to confirm.
Can I use the same labels for Evri and Royal Mail? Yes, both use a 100 × 150mm format, so the same 4x6 direct thermal roll prints both carriers cleanly.
One label stock, every carrier
Print Evri, Royal Mail and courier barcodes on the same 100 × 150mm direct thermal roll, no ink, toner or carrier-specific stock.
Shop 4×6 Labels