Hi Doug,
Thank you for the image. Indeed I can see that the second label has a longer UPC than the others. I presume that this value in fact has the same number of characters as the other invoices. Just to ask the question.
My test was to post an invoice with 10 digits in the document number, set 3 labels to print, then printed with the sample spec 'Label 5x Laser' with the Invoice number formatted using the bar code font. This spec is set to print 5 labels per page. I don't see a difference in the width of the UPC on the second label.
[img]
http://www.screencast.com/t/CY33g07zNNw[/img]
Same thing if I chose the sample 'Label Tec printer' spec, which is 1 label per page. All UPC codes are the same length.
You'll probably need to get your Adagio consultant involved, as this scenario appears to be more than what could be handled on the forum.