Like many ubiquitous items we use in our everyday lives, envelopes (regardless of size or type) have to be manufactured before they can be put to use. The manufacturing of envelopes — known as Envelope Converting — is a multi-step process wherein rolls or sheets of paper are die cut, folded, and glued to create an envelope.
Stock Envelopes
Envelopes are manufactured in a wide range of sizes and types to address various uses and needs. Generally, envelopes are manufactured in bulk and utilize a handful of common paper stocks. These envelopes are then sold through office supply companies or warehoused until needed by commercial printers for customer jobs. Due to widespread availability and low cost, stock envelopes in standard sizes and types are most frequently used in printing.
Custom Envelopes
In instances where a stock envelope does not meet a specific need, a custom envelope can be manufactured. Sometimes a client may require an envelope of a specific, non-standard size with custom die-cut windows. Or for example, a client/organization may choose an uncommon paper stock for identity materials (letterhead, business cards, #10 envelopes) that doesn’t offer a pre-manufactured, stock envelope and an envelope will need to be manufactured. Typically, when custom envelopes are a necessity, printing is done before the envelopes are cut, folded and glued. Also, custom envelope orders will often have set quantity minimums ranging from 5,000 to 10,000 pieces.
Bleeds
Any envelope printed in one-color or full-color front and/or back with bleeds, must be printed while the paper is flat and then made into an envelope. Thus, it’s always a good idea to consult with your printer when contemplating a printed design for an envelope where ink reaches the folded edge of the envelope. Such an envelope will need to be custom manufactured.
Custom Sizes & Features
Envelopes can be custom manufactured in non-standard sizes to fit specific needs. For instance, a uniquely-sized envelope can draw attention to a mailer or other promotional item. As mentioned above, an envelope with a specially-sized, shaped, or placed window may be desired. A custom printed security tint on the inside of an envelope (intended to block read-through) featuring a company’s name or logo would require a custom manufactured envelope. Other specialty finishes, like embossing or foil-stamping can be applied to envelopes. Although, in the case of embossing, if it’s desirous not to have the de-bossed impression show on the back of the envelope, a custom manufactured envelope would be the solution.
If you have any questions about Envelope Converting, give us a call at 330-597-8560. We’re happy to help you get the most out of your printing project.
