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Pushing the Envelope Beyond Ordinary

Custom Envelope Manufacturing Tips

Posted by Jerry Velona on Sep 26, 2012 10:13:00 AM

Elite Envelope is one of six remaining envelope manufacturers in the six New England states.  Nationally, the number of companies that actually make envelopes is shrinking due to lower overall demand but it is still a robust industry with dozens of plants spread throughout the country.  When you’re dealing directly with an envelope converter or manufacturer (same thing ) ordering  a custom envelope for a specific requirement is a fairly straightforward process. However, there are some things to keep in mind and here are a few of them:

Elite Envelope manufacturing

Quantity: - Many companies will enforce a 5,000 minimum for special-make envelopes.  Like most orders in the printing and envelope industry, the set-up for the job is a significant part of the total cost and it takes around five thousand impressions or envelopes to amortize that expense.  This means that if you order fewer than 5,000, assuming the company will allow for it, you’re really paying just about the same price overall that you would have for the 5,000.  At Elite, we will make fewer than 5,000 but there would be a minimum charge regardless of the quantity.  Some customers will just have us make 5,000 since they are in effect paying for them anyway.

Window Size,Position and Type: - If you’re designing a custom envelope with a window, it’s good to keep in mind that the edge of the window can be no closer than 3/8” to any edge of the envelope. This is because the patch that covers the window needs at least that much space to be glued properly.  Window sizes can run from full view which exposes virtually the entire front panel to small circles or special sizes and shapes (my favorite is the butterfly shape we used for a non-profit nature organization’s mailing).  Window material ranges from the most common synthetic poly to the bio-degradable corn-based product.

Size and Construction - When designing a custom envelope, the size is going to be driven mostly by what goes inside. It’s good to keep in mind the wide variety of standard sizes that might be close to what you’re looking for. It’s always going to be less expensive to use a stock item if possible.  Elite Envelope has a pocket guide which among other things lists all of the standard sizes. We’d be happy to send you one with our compliments. Simply click here.  It’s also a good idea to keep in mind the postage requirements based on certain size envelope. Elite Envelope Manufacturing

Function: - Lastly, if your envelope requires automated inserting, the specs of your particular inserter should be consulted to ensure that what you are designing will function properly.  All equipment varies with regard to what is acceptable.  The most important aspects to check are the size and shape of the flap and the depth of what is called the “throat”. That is distance between the flap score or fold and where the back panel of the envelope begins. In my experience, I’ve found that the smaller the inserter, the more careful you need to be about these aspects as they tend to be more temperamental with fewer adjustment options.

Topics: elite envelope, elite envelope, envelope manufacturing, envelope manufacturer, envelope questions, envelope buying guide

Envelope Questions? Elite has the answers

Posted by Jerry Velona on Sep 6, 2011 11:55:00 AM

Many of you have checked out my various posts in which I’ve detailed aspects of the envelope manufacturing,envelope converting and envelope printing processes.  For something as pedestrian as an envelope, there are certainly many issues that can be confusing.  Whenever we take someone for a plant tour, one of the comments that invariably comes up is: “Gee, I didn’t realize that so much went into making envelopes”.  (or some variation of that comment – “Gee” isn’t always included).

Envelopes have a variety of standard sizes and construction styles.  There’s also a very specific technology involved in creating an envelope whether it’s printed or unprinted. There is an entire nomenclature associated with envelopes to describe the various types as well as certain characteristics inherent in those types.  It can be confusing, especially to someone who doesn’t have a paper or printing background.

For this reason, Elite Envelope has developed the “Envelope Buying Guide”. This is a handy desk-reference that contains the basics including a list of the standard sizes along with descriptions, the most important terms you’ll need to know, a diagram of an envelope and things to keep in mind when purchasing an envelope.

We’ll be more than happy to send you a free copy for you and your colleagues. Just comment on this post with your name and address or send me an e mail through our website at and I’ll get one right out to you. 

As an envelope manufacturer, converter and printer, Elite Envelope is a direct source for all your envelope requirements.  We think that the more you know about envelopes, the better we look.

Looking forward to hearing from you!

Topics: elite envelope, elite envelope, envelope printing, envelope manufacturing, envelope manufacturer, envelope converting, envelope solutions, envelope questions, envelope buying guide

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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