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Mechanical Folding and Inserting Is Quick and Efficient
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Mechanical Folding and Inserting Is Quick and Efficient

When you want to free up valuable staff time and get your materials into the mail stream without delay, Mail Services' high-speed document inserter can meet your needs. Even better, it can tailor each set of enclosures for specific recipients by pre-coded address database. It can also insert personalized documents of variable length such as financial statements.

Whether you have items that require folding (cut sheets) such as letters, or separate enclosures such as return envelopes, brochures, fliers, or postcards, we can put it all together for you in one continuous manufacturing operation that includes mechanically folding, gathering, and inserting.

The number of possible inserts that can be gathered and folded depends on the fold style and envelope size. For example, up to seven cut sheets can be accordion folded and inserted into a number 10 envelope. Up to ten sheets can be half-folded and inserted in a 6.5 " x 9.5 " envelope.

In addition to these cut sheet capabilities, up to six different enclosures can be mechanically added to the mix.

We can give you ideas about how our intelligent inserting capabilities using OMR (Optical Mark Reading) control marks added to the document print stream can support your processes. If you would like more information, call Mail Services at (734) 764-9227.

Envelope Inserter Specifications
  • Minimum envelope size: 3.25" x 6"
  • Maximum envelope size: 6.5" x 9.5"
  • Flap depth: 1" to 2.3125"
  • Cut sheet inserts, accordion fold 8.5" x 7" to 8.5" x 14"or half-folded
    (the number of inserts that can be gathered and folded depends on the fold style and envelope size.)
  • Enclosure inserts, pre-folded or flat: 3" x 5.5" to 6" x 9"

Choosing the Right Envelope for Mechanical Insertion
Not all envelopes can be processed mechanically. Envelope paper stock may range from 20# to 28#, 24# is suggested. Check with Mail Services on envelope seams, window placement, flap and throat requirements. Envelope dimensions should not vary more than +/- .0625."

Calculating Envelope Width
  • Measure the width of the largest enclosure
  • Add the thickness of the entire collation
  • Add .125" (as a general rule of thumb, the width of the largest insert should be .5 " shorter than the width of the outside envelope)
Calculating Envelope Depth
  • Measure the height of the largest enclosure
  • Add the thickness of the entire collation
  • The height should be .25" to .50" shorter than the outside envelope


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