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Pushing the Envelope Beyond Ordinary

Custom Envelope Variation – part two

Posted by Jerry Velona on May 5, 2017 11:40:45 AM

In our last blog we presented the issue of variation in envelope converting and the reasons why it happens. In today’s piece, we’ll add the third and final reason for variation; jet offset envelope printing.

Envelopes can be printed in 3 ways (that topic to be fully discussed in a future article). The type of printing where variation can come into play is Jet offset printing. This is when the envelope is made and then printed after the fact.  In the typical Halm jet offset printer, a stack of envelopes is placed on one end and through vacuum pumps is fed through the printing cylinder over the plates and printing blanket and out the other end.  Like the envelope folding machine which forces the envelope to travel over a distance to its final destination, the printing press brings the envelope through various stages which cause it to move slightly.

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If the envelope is being printed with the same copy for each item and going through the press once, the amount of variation is so slight as to be virtually undetectable. However if, say,  you have a company logo that has been pre-printed onto the envelope and you are then feeding those “shells” into the press to add a certain return address next to the logo, you could see some variation or “bounce” in the placement of the return address in relation to the logo.  As in folding, the variation is generally within 1/16” of an inch but it could be more on a larger envelope like a 9 x 12.

Which brings us to things you can do to minimize the variation in your custom printed envelopes or custom envelopes in general; here are a few ideas you can put to use:

  1. Be realistic with your design – Certain designs for envelopes are almost sure to be a problem. Perhaps the most common one is designing the flap to be fully covered in a certain ink color. This looks cool but unfortunately the variation inherent in the process will cause there to be either some white on the flap or some color folding over of the color to the front of the envelope. The best way to avoid this is to either end the color 1/8” below the score line or wrap-around the color to the front 1/8”. It might not look as sharp but you’ll get a much neater and more consistent look.
  2. Avoid gloss coated stock where possible – Yes, it’s shiny and looks and feels great but it is also much more difficult to handle and the slipperiness of the coating causes more movement in the paper both in cutting and folding which can bring about greater variation.
  3. Deal directly with an envelope converter – Those of us who do this type of thing on a daily basis will be more familiar with the potential pitfalls and how to avoid them.

Have you had any problems with envelope variation on your printed pieces?  Contact us and we will provide an analysis of the problem at no charge or obligation to you.   

Our commitment to customer service never varies!

Topics: envelope printing, envelope printing mistakes, Envelope variation, custom envelopes, envelope variation solutions

Custom Envelope Variation – Why?

Posted by Jerry Velona on Apr 4, 2017 10:35:31 AM

Manufacturing an envelope in any size or type; custom envelope, specialty envelope or even a standard envelope involves several distinct processes.  Envelope converting can be a little confusing especially for someone not familiar with how it’s done.

One of the most common concerns from customers of envelope converters is the degree of variation in the product.  By variation, we mean the slight differences in overall size of the envelope, window placement and print placement from what was ordered.

Variation is the result of the three main stages that paper goes through to become an envelope: cutting, folding and gluing and, in some cases, envelope printing.  Another major factor is the nature of the raw material; i.e. paper.

Envelope blanks for converting.jpg

Cutting:  The unfolded piece of paper that becomes an envelope is called a “blank”. Blanks are cut by placing a steel cutting die that resembles a cookie cutter (except much bigger and heavier!) on top of a large ream of paper. The die is then pressed down by the cutting machine until it goes through the entire ream or “lift” of paper.  Paper is a naturally pliable substance.  As the die cuts through the ream, a slight bending or bowing can occur until it reaches the bottom and the paper ream “breaks” at which time it will lay flat.  That slight movement during cutting can cause some of the blanks to vary in size by as much as 1/16” from others.  The hardness or thickness of the paper can be factor as well as the sharpness of the die and the number of sheets in the ream. But ultimately, some variation as a result of die-cutting is unavoidable.

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Folding:  Once the blanks are cut, they are then loaded into the machine which applies the glue and folds them into a finished envelope. The typical envelope folding machine is between 20 and 30 feet long. The envelope blank will run all the way from one side to the other and then back again through scoring blades, window panel cutters and glue stations.  While envelope folding equipment is engineered for precision, there is a certain amount of movement during the process that is normal and, unfortunately, unavoidable. That movement can account for an additional variation of up to 1/16”.

In our next post, we’ll finish up the reasons for variation and also discuss some strategies customers can take to minimize its effect.

Topics: specialty envelopes, envelope converting, Envelope variation, custom envelopes

Custom Envelopes and "Overs"

Posted by Jerry Velona on Mar 16, 2017 10:29:58 AM

One of the most persistent questions posed by customers ordering specialty envelopes is, “why am I being billed for more (or fewer) envelopes than I ordered?”  Ah yes, the dreaded “over/under” question!

Annoyed designer gesturing in front of her laptop in her office.jpeg 

On custom envelope jobs, most envelope converters and printers will mention the possibility of more or fewer pieces being produced on the customer’s order.  Many customers tend not to pay attention to this; especially ones who are new or not familiar with the process.  Then, when the job or invoice is received, the howling begins.  It’s understandable for sure.

Despite what might seem to be a brazen attempt to increase the order under a dubious pretext, there is a very sensible reason why envelope converters maintain this policy. That reason is centered on the waste involved in the process. 

Let’s say a customer is ordering 5,000 special double window envelopes on a special stock.  There are two main processes in the manufacturing of envelopes. One is die-cutting of the paper (and maybe one of the windows) and the second is the actual folding and gluing of the paper to create the envelope. 

Setting up the paper to be cut involves placing a die in just the right position. Whether it’s done manually or automatically, it takes some trial and error before the cuts come out just right.  Until that point there are numerous sheets that are cut and discarded.  Then, once the paper is cut, setting up the folding machine and getting the specs exact also requires a lot of “make ready” paper.  Lastly, once the machine is running, constant fine adjustments must be made to keep the job running properly.  This can involve numerous stops and restarts which waste more paper.

In order to have enough paper to allow for possible contingencies, a company must order a significantly higher amount which adds cost to the job.  Being able to bill for a reasonable amount of “overs” allows a company to cover these added costs while providing extra envelopes that a customer will more than likely be able to use.  The alternative is for a customer to specify at the quoting stage that they do not want an overage on their order. What most companies will do in this case is simply include their extra costs into the price.  Under this scenario, the customer will pay the same overall cost for his job but without the benefit of more envelopes.  

“Unders” or receiving a quantity less than the amount ordered is also a possibility. It is less common however as getting less is generally a bigger problem to customers than getting more so companies will try to buy more than enough paper to ensure that the count is met.

What is a “reasonable” amount of overs or unders?  In the envelope world, generally the figure is up to 30% on minimum quantities and then the percentage declines as the quantity of the order goes up.  The higher percentage of overs would apply to more expensive specialty envelopes like custom Tyvek envelopes, bubble mailers and poly mailers.

Topics: bubble envelopes, tyvek envelopes, specialty envelopes, envelope converting, custom envelopes, overs/unders, envelope converter, poly mailers

Top Five Envelope Custom Envelope Converting Tips

Posted by Jerry Velona on Feb 27, 2017 11:12:35 AM

Envelope converting can be a confusing and somewhat daunting experience for someone not familiar with the process.  For printed envelopes, the term simply means printing on a flat sheet and having the sheets die cut and then folded and glued into envelopes.  The term also applies if you’re just cutting the paper with no printing. You are “converting” sheets of paper into envelopes:  pretty basic stuff.  Once you’ve gone through the process for the first time; it becomes much clearer and easier to understand.

Maybe you’re thinking about designing a custom envelope for a customer. Or maybe you’re an envelope printer and your customer is asking about a specialty envelope.  Here are a few things to keep in mind for your first converting job:

  1. Deal directly with an actual converter – Many companies that sell envelopes and have the word “envelope” in their name are not converters. It’s best to ask first before sending over an order.  You’ll be better served by those more experienced in the process and doing the job in-house.
  2. Preparation is the key to good results - A good converter should provide you with a specific list of instructions before you begin. Most important is a layout of the printed sheet showing where the envelopes should be placed. They will help you through the process.
  3. Not all design ideas are created equal - If the envelope is printed with a solid that bleeds to an edge, the image must wrap-around to the back by at least one-eighth of an inch in order to account for the normal variation inherent in the process. For window envelopes you can bleed the copy right to the edge of the window when converting. This is not possible with regular envelope printing on a pre-made envelope
  4. Understand what is possible in the process – speaking of variation, this is something that many designers don’t take into account when creating their envelope. Cutting paper in large reams and folding and gluing involves some variation – generally one-sixteenth of an inch in either direction.  This needs to be understood in order to have a satisfactory result and a realistic idea of what to expect.  Something that looks great in a direct mail marketer’s imagination doesn’t always translate to the finished product.
  5. Why convert? – If you want an envelope that features a large amount of ink coverage, generally with bleeds on most or all sides, the best way to proceed would be to print on flat sheets and convert. Anything short of that might be able to be printed on a jet press using pre-made or stock envelopes at a much lower cost. A converter and printer will be able to advise you on the best way to go on your specialty envelopes based on a simple inspection of your artwork.

 Envelope types.jpg

Custom printed envelopes can enhance your image and cause a potential buyer to be curious enough to at least open it up.  Choosing the right envelope company; one which does the envelope converting, printing and manufacturing under the same roof and can make the process easy to understand, is a good place to start.

Topics: envelope printing, specialty envelopes, envelope converting, custom envelopes, envelope converter

New Years Ruminations & Some Good News for Mailers

Posted by Jerry Velona on Jan 24, 2017 10:05:23 AM

First of all, Happy New Year to all those who follow and read my blog. I wish everyone the best for success and happiness in 2017.  Despite the fact that I write this in a cold weather climate (Boston) and the days are short, there’s always a certain positive energy associated with a new year at least to me. It’s a clean slate; time to refresh the screen and figure out what’s possible.  Of course the figuring-out part is a lot easier than the executing part.  I think that’s where a lot of people get stuck in the mud. Oh well, it’s always worth a try! 

I always wonder how far into January you go before you stop wishing people happy new year. I write this on January 22nd. This will definitely be the last week where I’m extending those wishes.  Don’t ask me why. It just seems about the right time to end it.

Of course before we know it, everyone will be saying, “I can’t believe it’s March/April/May already”.  So the moral is, make the most of 2017 because it will be over before you realize what happened.

One last thing on New Year’s and good intentions; one of the hardy perennial new year’s resolutions is to be more organized. With the amount of raw data most of us are bombarded with each day, I think it’s more important than ever to be able to sort through the never-ending amount of digital messages we receive and still have time to be productive.  My friend Lorena Prime has a very successful company called “Clearly Organized”.  Her website has lots of useful information and Lorena does seminars and consulting for business and individuals.  Lorena’s great and I encourage anyone who has that problem or runs a business where it’s a problem with staff to contact her.

So, as we know everything in life involves trade-offs. The information overload and fatigue it can cause is one side of the coin. The other side is how much great information is out there literally at our fingertips which can help us and save us time and money. 

I happened to come across a great article by Adam Lewenberg of Postal Advocate in Wayland, MA.  Adam writes for Mailing Systems Technology magazine and has analyzed and broken down the new postal rates that have taken effect on January 22nd, 2017. 

Overall, the rate increases are minor and they contain some good news for direct mailers and direct marketers as well as those that supply direct mail printing and printed envelopes for direct mail. 

Perhaps the biggest and best news is that automated (pre-sorted) mail will have a single, flat rate from 1 ounce up to 3.5 ounces.  This will enable marketers to put a lot more in the envelope for the same price.

Adam’s article has a whole bunch of useful information about the new rates along with some tips on how to save money on your next campaign.  Kudos to him for laying this out in such a clear and concise fashion.

So again,  Happy New Year (for the last time in 2017) and may all your direct mail campaigns be smooth and effective!

Topics: direct mail, elite envelope, post office, direct mail printing, printed envelopes

Elite Envelope Goes Solar!

Posted by Jerry Velona on Dec 14, 2016 12:33:24 PM

So I was shocked twice this morning.  First, when I realized I hadn’t written a blog entry in over a month (I know, I know you’ve all been sitting at your desks each morning wondering where it’s been). And secondly when I looked at the calendar twice to see that it’s indeed December 14th and Christmas is next Sunday(!)  

 Rather than try to explain the inexplicable; i.e. how another year has apparently come and almost gone, I’m going to jump right into the topic of the day which is the value of renewable energy in the printing and envelope industry and the importance of accurate claims in this regard.

 As anyone who follows this blog is aware, I’ve been skeptical of the claims made by some of our competitors that a particular envelope was manufactured or printed using wind power.  In fact, “skeptical” may not be the right word.  “Dismissive” might be more accurate.  The way this works is that a company will purchase what are known as Renewable Energy Credits or REC’s.  These represent a purchase of a certain amount of power that is actually produced by a random wind farm somewhere in the US. The theory is that the power once purchased goes into the grid and is available for use by someone/anyone.  So this energy is thought to replace power that would have been produced using conventional fossil fuels.

I’ve always thought this to be a bit squirrelly and you can read why here.   But I’ve also said that if you really want to make a difference and think that renewable energy is important, then by all means put your money where your mouth is and you’ll get no quarrel from me.

That’s what we’ve done at Elite Envelope & Graphics.  As of the beginning of 2017, we will begin generating somewhere between one half and three quarters of our total energy consumption through an array of solar panels that we’ve just installed on our brand new roof.

Elite Solar JV standing.jpg  

To be honest, our primary reason for doing this was economics.  Between the incentives provided by the Federal and State governments, the system will pay for itself in a fairly short time after which our monthly savings on electricity will be substantial well into the future. And once all the impending breakthroughs in large, storage battery technology I’ve been reading about come to fruition, it’s possible that we could be completely self-sufficient in our energy usage in the not-too-distant future.

But aside from the economics,  there are certainly environmental benefits to consuming less fossil fuel and we will now be in a position to print this (below) on our customer’s envelopes and have it be literally accurate.  There’s a lot to be said for truth in advertising!   Let us know if we can help you impress your customers.

Solar Power Logo Sun.jpg

 

Topics: elite envelope, envelope printing, envelope manufacturing, going green

Bubble Envelopes & Recycling

Posted by Jerry Velona on Nov 3, 2016 2:33:50 PM

I was raised not to waste. As a child growing up in the northern New Jersey suburbs, wasting anything was one of the worst things we could do. The ethic of conservation around our house was neatly summed up in the aphorism quoted to me innumerable times by my grandmother and my mother: “use it up, wear it out, make it do or do without”.  I also heard, “waste not, want not” more than a few times for good measure. We were the children and grandchildren of the generations that lived through the Great Depression and the hard lessons of that era were drummed into most of us growing up in the 60’s and the 70’s. 

 I don’t believe I owned a pair of “play pants” (as they were quaintly referred to) that didn’t have multiple patches stitched into them by my grandmother and her trusty Singer sewing machine.  When I’d make another hole (we played hard back then!) I’d just get another patch. It was no big deal and nothing embarrassing to me.  And we weren’t poor, by the way.  We lived in a small but comfortable single family home in a solidly middle class neighborhood.

 patches on pants.jpg

Can you imagine someone these days doing that?  Now there are many reasons why you see very few patched pants on kids today.  Probably the biggest one is that the general level of affluence in society among all economic groups is greater than it was 50 years ago.  There’s less of a need to patch pants when you can afford to just buy a new pair for a reasonable price.  Another factor is personnel-related. How many families have an in-house grandma who’s got the time, skill, equipment and willingness to do it?

 Today the cultural ethic of conservation and recycling has mostly become the province of environmentalism. I have mixed feelings about this development. On the one hand I think it’s good to carry on the traditions of frugality regardless of the rationale. But I tend to look at these things more from a moral perspective rather than just a “green” perspective. The two are not always in synch. But, that’s a topic for another day!

What I’ve been leading up to here is that it’s good to recycle and reuse and that at Elite, we have come up with a way to allow you to reuse your bubble envelopes while still having it your way.  The answer is our Smart Bubble ™ product.  Like all good ideas, it’s very simple. We print you an envelope in however many colors you want, with as much coverage as you’d like and we provide it with a removable bubble sleeve.  We can do these in small quantities if you’d like with the same quick turnaround we provide on just about everything we make.  The removable sleeve can be re used or recycled.  Sometimes it’s good to have the item that’s been shipped in the envelope stored in the same protective packaging once it’s removed.  Or you can use the liner to send something else or add protection to something you’re shipping in a box.

 With Elite’s Smart Bubble™ envelope, you can have your favorite design and ship it too.  (Patches not included!) 

Topics: elite envelope, bubble envelopes, smart bubble envelopes, recycling envelopes

Envelope Manufacturing at the Smithsonian

Posted by Jerry Velona on Oct 17, 2016 3:22:07 PM

On September 13th, the Smithsonian's National Postal Museum launched a new virtual exhibition, "America's Mailing Industry", telling the story of the partnership between the U.S. Postal Service and private industry, which together have helped American citizens and businesses communicate and conduct business for more than 200 years.

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The website is very well done and contains a great deal of historical information about mail, direct mail, the Post Office and the various businesses that support mail communication and delivery.  With regard to envelope manufacturing there are many interesting tid-bits about how envelopes used to be made (by hand mostly) and the advent of the first machines which could get up to 150 envelopes per hour (!).

Aside from envelope companies, printers are well represented and there’s a neat little summary of the history of printing in the United States marked by the various technological improvements along the way.  There are additional sections on letter shops, paper companies, graphic designers, non-profit fundraisers, newspaper publishers, catalog and mail order companies and many more. Each section has a succinct description of the business, its history and how it relates and the contribution it makes to the flow of mail.

I’ll admit to having some mixed feelings when reading through the site.  Usually when you say something “belongs in the Smithsonian” it means it’s a historical artifact of a bygone era. For instance I’ve driven some cars that looked like they “belonged in the Smithsonian”. (and had a lot of fun driving them I might add).  Those of us in the print, mail and envelope industries spend a lot of time talking about how the industries are still relevant in the digital age – and they are.  Print, paper and mail are still the medium of choice by millions for selling and communicating. But there is that nagging thought that the industries are not what they were 50 or even 20 years ago and that maybe the next step is to start writing the history as if they are in the past tense. 

So seeing our industry featured in a Smithsonian exhibit (in a web site no less!) can stir some of those thoughts.  But the Smithsonian also features exhibits on the aerospace industry and other thriving businesses.  Its purpose is to provide history and context and demonstrate what initiative and ingenuity can do through individual and cooperative effort.

modern_postal_facility.jpg

I urge you to check it out at the link above.  Now it’s time for us in the business to get back to making more history!

Topics: direct mail, post office, envelope manufacturing

Print, Mail & Envelopes in the New Century

Posted by Jerry Velona on Sep 16, 2016 3:20:45 PM

Ask most anyone these days in the print, mail or envelope industry about the current state and future of mail and you’ll generally get an answer that’s hopeful but cautious.  The great digital disruption of the last 25 years or so has caused an irrevocable change in printed communication.  Those of us who’ve seen these changes as they’ve occurred are naturally wary about what is to come.  It hasn't always been pretty!

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On the one hand mergers and acquisitions continue apace with smaller, less capitalized companies unable to profit in the new landscape and selling out (if they’re lucky) to larger firms more able to diversify and adapt to changing market conditions. Obviously, creative destruction is part of every sector of the economy and generally indicates overall health in the market. But it does seem that there’s more of it going on in our industries of late and it’s been accelerated by the ubiquity of smart phones among other things. Not a week goes by when we don’t receive some notice of an equipment auction. Used envelope and printing equipment has never been less expensive and more available. That’s a tangible sign of over-capacity due to a still-shrinking market.

However on the other hand direct mail is certainly coming back with a vengeance.  After a relatively brief flirtation with relying exclusively on digital-based marketing, fund-raising companies as well as colleges and other large institutions are coming back to mail solicitations because they achieve better results even with the added costs of printing, envelopes and postage.  And at Elite Envelope, we have seen a significant increase in new customers comprised of small start-ups ranging from print brokers, consultants, marketing agencies, and craftspeople making a high value product that needs to be mailed in a printed bubble envelope or promoted with a full-color package including a window envelope and reply envelope.

We speak to customers every week who are changing their business around; getting into providing new services and products to customers in order to capture more of their business. And far from being the bane of our existence, technology is enabling us to work smarter with more information at our fingertips and marketing software and website apps which allow a one-person marketing “department” to reach thousands (or millions) of potential customers with a few clicks.

It might sound contradictory for companies in the print communication business to use website and e mail to such an extent to promote their wares but it’s really not.  It’s all part of the grand, shaking-out and reorganizing that’s going on not just in our industries but in just about every business across the entire economy.  And what we’re finding is that print and mail is settling in to have its place in the mix of ways people communicate, sell and solicit.   It’s up to us to increase the value of what we provide and hopefully our share of the market.

Topics: elite envelope, envelopes and printing, envelope industry, declining mail volume, printed bubble mailers

Paper Comes Back (or it never really left)

Posted by Jerry Velona on Jul 19, 2016 12:59:35 PM

One of the most predictable things in life is that changes and trends tend to move drastically in one direction only to be followed by a re-calibration.  It’s part of our nature to become infatuated by something new and different.  But after the full effects are consumed and digested, things tend to settle back into some rough equilibrium.  

Of course this isn’t true in all cases.  Once the automobile came onto the scene, horse-drawn transportation became a decidedly niche activity and stayed that way.  But not all social trends or new technological developments are as obviously superior as the car. 

It’s remarkable to think that the internet as we know it and use it today has really only become widespread within the past twenty years or so. The world has profoundly changed as a result and it’s been a positive change in almost all respects.  

High technology in all its forms has pushed paper aside in many ways and for many reasons; some having to do with convenience, some with cost, some with (often faulty) environmental concerns.  But inevitably, the “digestion” period has begun and people are starting to process these changes, seeing the negatives as well as the positives and acting accordingly.

A few recent examples illustrate this:

Item - In a June 22nd article in the Boston Globe - "Millennial's strange love affair with greeting cards" Janelle Nanos writes about how young adults are seeing the superior personal connection of a written note and card versus a "throwaway" message on Facebook or Snapcha and are buying them in significant quantities.  The demand is mostly fulfilled through small, boutique card companies that market online.  Improved printing technology and lower upfront costs have reduced the barrier to entry in the market.

Item – In a July 10th essay in the Wall Street Journal entitled "I'm Banning Laptops from My Classroom" , Rutgers law school professor Stuart Green makes his case against the use of computers in his class. His reason quite simply is that many students are distracted and doing other things rather than listening and engaging in the lecture.  He seems this as an endemic problem in society as a whole especially among Millennials – a state of perpetual distraction.  Starting this fall, students in Professor Green’s class will have to go back to writing notes on paper.

Item – An article in Fortune magazine from April 16th, "Air Dryers Disperse Viruses" summarizes a recent study conducted by the Journal of Applied Microbiology which showed that hand dryers, in particular the Dyson model where you stick your hands in, spread germs wildly around the restroom as opposed to using a paper towel which confines the germs primarily to the trash.  Now, I’ve read where the methodology of this study might have exaggerated the results. I haven’t read the study. But the conclusions seems to pass the common sense test at least to me.  (Personally, I’ve always preferred the paper towel to the air dryer).

Item – In an Info Trends blog dated June 7th, entitled "Millennials Won't Respond to Printed Catalogs and Direct Mail, Right? WRONG!" data is presented to demonstrate the headline’s thesis.  I have to say that even I was surprised at the findings which showed a very high percentage of the 18-34 age group studied finding catalogs useful and opening direct mail pieces they receive.  The article makes the point that after a period of decline, both catalogs and direct mail are experiencing a resurgence because they get results.  Sound familiar?

So are we seeing a return to paper and printing on paper and envelopes as a general counter-trend?  I’ve presented some anecdotes which don’t conclusively prove the point but I believe they are indicative of the type of re-evaluation I alluded to earlier.  In my experience with Elite Envelope and Graphics, I can attest to the fact that custom made card packages for invitations and other purposes are becoming more and more popular. Some of our fastest-growing customers are in that market.

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I was going through some old photos the other day and mixed in with them were some letters I had received from my mother while in college.  My Mom passed away in 2002. What a joy it was to read those letters written in her impeccable penmanship and expressing herself in the erudite yet personal manner she was known for.  Print on paper can connect us to our past (and present) in a way that the ephemeral digital form of communication cannot. Unless of course, you print them out and save them!

 

Topics: elite envelope, envelopes, printed paper, paper;

Yet Another Blog Post

From Jerry Velona - co-owner,

Elite Envelope & Graphics, Inc.

Jerry offers pertinent, often useful information on envelope converting and printing, web printing, direct mail, the post office, songs that have to do with mail and letters, digital overload and much more!

(Non-spam) Comments always appreciated.  Spread it around!

 

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