I use 2.5" round labels. I have tried Planetlabel, Avery, and BCN labels. I have tried the avery template, the planetlabel template, printmaster, etc. I also have a different printer now than I used to. I have calibrated the printer. No matter what I did, I was having the same problem as you. I finally re-made my label to not fit entire the entire backround and then you don't notice small differences. I think it's just something with those darn round labels. Wish I could give you positive news but I tried for a long time with many things and that is just what I came up with.