Litho Print and Convert Envelope Printing: Key Benefits & Applications
Lithographic envelope printing, often referred to as “litho print and convert” or simply “litho/convert,” is a widely used process known for producing exceptional print quality. Here’s everything you need to know about litho/convert envelope printing – what it is, key advantages and limitations, and when it’s the best choice for your envelope printing needs.
What is Litho Envelope Printing and Converting?
Lithographic envelopes are produced by offset printing – the gold standard of print quality. Traditionally, lithographic envelope printing involves:
- Producing a unique metal plate for each color, typically CMYK (though litho envelopes can also be printed in 1-color, 2-color, or multiple PMS colors)
- The metal plates and rubber blankets are placed on cylinders that transfer oil-based ink to flat sheets, printing the envelope design
- After the flat sheets are printed, they are then converted (cut, folded, and glued) into envelopes
A newer process called roll-to-roll convert is also available for higher quantity jobs. With roll-to-roll convert:
- Envelopes are printed on a roll instead of a sheet
- The machine can die-cut and convert inline – an all-in-one, one-step process instead of two processes
- It can also emboss and add perforations, openings, and special windows
- You can get lithographic-quality printing in a more economical roll format versus flat sheet printing
Roll-to-roll technology can potentially reduce envelope printing costs (depending on the size of the project).
Litho/Convert Advantages
Here are the primary advantages to litho/convert envelope printing.
Print Quality
Litho/convert produces the highest possible quality with accurate color matching, so it’s ideal for applications where print quality and branding are paramount.
Complex Customization
The litho/convert process is ideal for complex envelope projects, such as those that require intricate die-cuts and unique sizes. Since envelopes are printed on flat sheets before conversions, special embellishments can be applied prior to or during converting, including:
- Unique perforations
- Custom windows and openings
- Embossing, such as a custom spot emboss
- Coatings
- Foils
Some embellishments can qualify your mailings for USPS discounts. For example, embossing could save 4% with the Tactile, Sensory & Interactive Promotion – and up to 6% total with add-ons like sustainable paper.
Interactive Openings
With litho/convert, you can also add interactive openings such as peel and reveal. This value-added service also qualifies for USPS discounts.
Versatility
Litho/convert is one of the most versatile envelope printing options, allowing for specialty inks, textures, and coatings. In fact, nearly any process that can be applied to a sheet can still be converted into an envelope.
Full Bleeds
With litho/convert, you can print envelopes with full bleeds for edge-to-edge color, which is commonplace in marketing mail and many other mailers.
Cost Effective Large Runs
Per-unit costs decrease with higher volumes, making litho/convert a cost-effective choice for large envelope runs.
Litho/Convert Limitations
Litho/convert does have a few limitations to consider for certain types of envelope projects.
Higher Set Up Costs
Offset envelope printing requires plates, which incur setup costs, so it’s not cost effective for short runs. However, you can save by taking advantage of in-house tooling and dies. For example, Priority Envelope has thousands of envelope dies and window sizes in our inventory.
Turnaround Time
Litho/convert can take slightly longer than jet printing due to off-line processes. That said, litho/convert projects can still be completed in 7-10 days of production time.
When to Consider Litho/Convert Envelope printing
Litho/convert envelope printing is a great choice for:
- High volume printing
- Superior quality, impeccable branding, and color matching
- Full bleeds
- Specialty finishes
- Control, as it offers printers more control over the printing process
Not sure if litho/convert is the right choice for your next envelope project? Priority Envelope is here to help. Our experts have decades of experience with envelope printing and converting, so we can help you choose the highest-quality, most cost-effective solution to achieve success at the mailbox.
