5 Processes Involved In Production Of Custom Printed Envelopes

5 Processes Involved In Production Of Custom Printed Envelopes

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Are you aspiring to start your own envelope production company? There are some basics you need to learn if you have never ventured into this business before.

Today, there are 2 types of custom window envelopes namely pocket envelopes (open end) and open side envelopes such as pointed, self-seal, booklet, and commercial envelopes. Basically, they are produced in 3 run sizes i.e. short, medium, and long runs. Short runs are generated on machines which start from pre-cut blanks; medium runs from equipment with dual feed, and long runs from rolls of paper. So, before an envelope machine is chosen, the envelope design category must be defined first as well as the required quantities. Basically, there are 5 processes of producing enveloped through the paper blank fed machine.


  • Die cutting

In this process, papers are cut into blanks. A die cutter uses dies to cut blanks in sizes of the final product. Dies are metallic knives which have the shape and size of envelopes. Factors used in the selection process include the speed, price, and size of the table. The hydraulic press and programmable hydraulic press are examples of die cutting presses. After the die blanks are cut, they are folded and the closing flap is gummed.

  • Printing

Basically, a printing press can print blanks on one side in a single color and 2 colors the other side. This process is referred to as flexographic printing where one flexo printing is done inside and two flexo printings made on the outside. Finished envelops can also be printed but only on the envelope’s outside. The criteria used in the selection process are the number of envelopes, size of envelopes, and the type of impression.

  • Window punching and patching

Once the blanks are printed the windows on blanks have to be punched and patched by the envelope machine. It is basically the process of cutting and patching the window film.

  • Folding

The printed and punched blanks are passed through a fundamental machine which will fold and glue the envelopes. This stage is crucial in the production process and it results in either open-end or open-side envelopes.

  • Gumming and sealing

Glue is applied on the edges of envelope blanks in this final stage. Dextrin gum/remoistable is used in most cases. A special type of gum can be applied to the envelope’s body or seal flap. Moreover, some machines open the flap of the produced envelopes and apply gum which may be latex, silicon tape, or dextrin.

The above operations can be carried out by a single envelope machine as a continuous process (on-line). The other option is to use different machines for every step (offline). Perhaps you want to start an envelope production company; you will need to invest in equipment specifically designed for short runs and production of open-side envelopes. Such machines can perform all the above functions from cutting, folding, punching, patching, and gumming. You, therefore, need to make a reasonable budget of say twenty thousand dollars. Since you want a machine with excellent printing abilities, you need an extra budget of thirty to fifty thousand dollars. The operations of such a machine involve sheets of paper.

If you need to produce envelopes in long runs, you require envelope equipment that uses rolls of papers known as webs.

It is said that information is power. Now you have an idea of how custom window envelopes are generated. Use this information to start an envelope production company of your dreams. All the best!


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