Envelope Converting Guide & Customization Options
While often overlooked, converting is a crucial step in the envelope production process – but what is envelope converting, and why does it matter? Our guide details what envelope converting is and explores various converting options to help you make the best choice for your next envelope project.
What is Envelope Converting?
Envelope converting refers to the process of transforming flat sheets or rolls into finished envelopes, either before or after printing. It involves cutting, folding, gluing, and applying embellishments such as windows, special openings, and adhesives.
Stock envelopes can be pulled from inventory for imprinting. Custom envelopes can be printed before, during, or after converting depending on what printing process is appropriate.
Converting Scenarios
Here are three common envelope converting scenarios.
Flat Sheet
In this scenario, flat sheets of paper are printed before converting. Flat sheets are ideal for high-end custom envelopes, since you can print full bleeds and apply embellishments such as embossing and interactive openings that qualify for USPS discounts.
Web
Continuous paper rolls are fed into presses for high-speed envelope production. Web is an ideal converting process for high volume runs, and is often the most cost-effective option at the right quantity.
Web machines can print, convert, emboss, and even produce interactive openings in-line for an all-in-one process that can save time (and sometimes money, depending on the project).
Blank
Unprinted paper is cut and converted to create blank envelopes. It’s a cost-effective option, but customization is limited. At Priority Envelope, much of our blank stock is manufactured in-line on web converting machines.
Options and Features
Common envelope converting options and features include:
- Side and diagonal seams
- Windows
- Custom flaps
- Closures (peel and seal, tear tape, etc.)
- Embossing and debossing
- Interactive openings
- Trailing edge die-cuts
Advantages of Custom Converting
While a blank envelope may have a lower price, custom converting offers benefits including:
- Customize every aspect of your envelopes and have total control over how they’ll look, feel, and perform at the mailbox
- Higher ROI since custom envelopes are more likely to be opened
- Full bleed printing
- Diverse material options
- Added features: windows, interactive openings, trailing edges, and other features – some of which qualify for USPS promotions
When to Consider Custom Envelope Converting
Custom envelope converting is a great choice when you need:
- Unique envelope designs
- Full bleed graphics
- Premium materials
- Specialty features
Not sure which envelope converting process is best for your next project? Priority Envelope is here to help. Our experts have decades of experience helping our customers choose the right envelope printing and converting processes to portray their brands and drive ROI.
