Envelope making process

Here is where the envelope is made. In the folding process, the die cut envelope blanks are fed into the folding machine. The flap glue is applied, the envelope can be printed flexo with 2 colors outside and also print the inside tint, windows are die cut and window film applied, seams are glued, and the envelope is folded. All this is done inline on the folding machine.

With a diverse mix of equipment and hundreds of envelope and window dies, Colorado Envelope can fold many envelope styles: commercials, booklet, catalog, announcement, remittance.

Colorado Envelope can also print converted plain envelopes.  These high speed jet presses can print two colors, two sides in one pass through the machine.  This is litho quality printing that can be as simple as line copy, or detailed graphics with tight registration and screens. Size range for 2 over 2 printing goes from 3 ½ x 5 to 9 x 12.  Larger envelopes up to 12 x 15 ½ can be printed 2 colors on 1 side.

A hydraulic press is used to cut the envelopes out of a stack of paper. This stack of paper (200-500 sheets?) is clamped together on a table that then slides into the press. A metal die, in the configuration of the unfolded envelope, is then pushed down through the stack of paper by the press making the envelope blanks. The cutting can be done on a Programmable Hydraulic Press (PHP) which automatically cuts and turns the die. A computer programmed layout guides the PHP through multiple cuts and turns to maximize the number out per sheet. Envelope die cutting can also be done on a manual hydraulic press. Here the die is set on the stack of paper by hand and then it slides into the press to be cut. This manual process is used for registering the die on pre-printed paper and also for smaller quantity orders.

In addition to these two cutting processes, Colorado Envelope is able to also cut envelopes adjustable if we do not have a die. So, if you need an odd size, or are designing a special project this may work. Adjustable cutting can make booklet or catalog styles. Paper is cut to the dimensions of the flat envelope blank required. Then four corner blades are positioned to cut out the corners of the sheets leaving the envelope blank.

We inventory well over a thousand dies of various types, sizes and styles. Our envelope dies range from your standard envelope sizes to all sorts of sizes and shapes. With our adjustable die we can make any size booklet envelope you desire that falls within specifications of the envelope manufacturing machines. As for window dies, we have almost any size you desire from single to double die setups.

With our adjustable die we have the ability to make any size booklet envelope you desire. You can customize the size of the flaps as well as the body of the envelope. This process is especially helpful when pricing small quantity orders. For larger quantities it is beneficial to have an envelope die ordered to your specifications.