Chapter 9: Envelopes and Folders

ENVELOPE CONSTRUCTION

This diagram shows the basic parts of an envelope. Refer to these terms when working with envelope converters or others involved in envelope printing and manufacturing.

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CLOSURE DESIGNATION

Closure designation is described by the location of the envelope opening and seal flap. Aesthetic and functional considerations should guide your decision on which of the following types to select.

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OPEN END (OE)

The opening and seal flap are located on the short dimension. Open-end envelopes are well suited to hand-insertion applications.

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OPEN SIDE (OS)

The opening and seal flap are located on the long dimension. Open-side envelopes are well suited to automatic as well as hand-insertion applications.

STANDARD ENVELOPE STYLES AND SIZES

Envelopes come in a variety of styles that vary according to function. Some styles are more suitable for invitations and announcements, while others are appropriate for business use. Each style is available in a range of standard sizes. Consult the diagrams and listings below to determine which style and type of envelope is best for your job.

COMMERCIAL AND OFFICIAL (UNITED STATES)

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Standard correspondence-style envelopes. Open-sided with gummed flaps. Made in a wide range of bond and kraft. Commercial sizes range from no. 5 to no. 6 3/4. Official sizes range from no. 7 to no. 14.

Item/No. 5
Size (inches) 3 1/16 × 5 1/2
Size (centimeters) 7.78 × 13.97
Item/No. 6
Size (inches) 3 3/8 × 6
Size (centimeters) 8.5725 × 15.24
Item/No. 6 1/4
Size (inches) 3 1/2 × 6
Size (centimeters) 8.89 × 15.24
Item/No. 6 1/2
Size (inches) 3 9/6 × 6 1/2
Size (centimeters) 9.05 × 16.51
Item/No. 6 3/4
Size (inches) 3 5/8 × 6 1/2
Size (centimeters) 9.2075 × 16.51
Item/No. 7
Size (inches) 3 3/4 × 6 3/4
Size (centimeters) 9.525 × 16.145
Item/No. 7 1/2
Size (inches) 3 3/4 × 75/8
Size (centimeters) 9.525 × 19.3675
Item/No. 7 3/4 (Monarch)
Size (inches) 3 7/8 × 7 1/2
Size (centimeters) 9.8425 × 19.05
Item/No. Data Card
Size (inches) 3 1/2 × 7 5/8
Size (centimeters) 8.89 × 19.3675
Item/No. 8 5/8 (Check)
Size (inches) 3 5/8 × 8 7/8
Size (centimeters) 9.2075 × 21.9075
Item/No. 9
Size (inches) 3 7/8 × 8 7/8
Size (centimeters) 9.8425 × 22.5425
Item/No. 10
Size (inches) 4 1/8 × 9 1/2
Size (centimeters) 10.4775 × 24.13
Item/No. 10 1/2
Size (inches) 4 1/2 × 9 1/2
Size (centimeters) 11.43 × 24.13
Item/No. 11
Size (inches) 4 1/2 × 10 3/8
Size (centimeters) 11.43 × 26.3525
Item/No. 12
Size (inches) 4 3/4 × 11
Size (centimeters) 12.065 × 27.94
Item/No. 14
Size (inches) 5 × 11 1/2
Size (centimeters) 12.7 × 29.21

BOOKLET (UNITED STATES)

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For use with booklets, folders, and other types of direct mail. Open-side design permits overall printing.

Item/No. 2 1/2
Size (inches) 4 1/2 × 5 7/8
Size (centimeters) 11.43 × 14.9225
Item/No. 3
Size (inches) 4 3/4 × 6 1/2
Size (centimeters) 12.065 × 16.51
Item/No. 4 1/4
Size (inches) 5 × 7 1/2
Size (centimeters) 12.7 × 19.05
Item/No. 5
Size (inches) 5 1/2 × 8 1/2
Size (centimeters) 13.97 × 21.59
Item/No. 6
Size (inches) 5 3/4 × 8 7/8
Size (centimeters) 14.605 × 22.5425
Item/No. 6 1/2
Size (inches) 6 × 9
Size (centimeters) 15.24 × 22.86
Item/No. 6 3/4
Size (inches) 6 1/2 × 9 1/2
Size (centimeters) 16.51 × 24.13
Item/No. 7
Size (inches) 6 1/4 × 9 5/8
Size (centimeters) 15.875 × 24.44475
Item/No. 7 1/4
Size (inches) 7 × 10
Size (centimeters) 17.78 × 25.4
Item/No. 7 1/2
Size (inches) 7 1/2 × 10 1/2
Size (centimeters) 19.05 × 26.67
Item/No. 8
Size (inches) 8 × 11 1/8
Size (centimeters) 20.32 × 28.2575
Item/No. 9
Size (inches) 8 3/4 × 11 1/2
Size (centimeters) 22.225 × 29.21
Item/No. 9 1/2
Size (inches) 9 × 12
Size (centimeters) 22.86 × 30.48
Item/No. 10
Size (inches) 9 1/2 × 12 5/8
Size (centimeters) 24.13 × 32.0675
Item/No. 13
Size (inches) 10 × 13
Size (centimeters) 25.4 × 33.02

TICKET (UNITED STATES)

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Open-side envelope for theater tickets. Often printed with advertising.

Item/No. 3
Size (inches) 1 5/16 × 4 7/16
Size (centimeters) 3.3350 × 11.2725

WINDOW (UNITED STATES)

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Permit name and address typed on the enclosure to show through the window. Used for invoices, statements, checks, receipts, etc.

Item/No. 6 1/4
Size (inches) 3 1/2 × 6
Size (centimeters) 8.89 × 15.24
Item/No. 6 3/4
Size (inches) 3 5/8 × 6 1/2
Size (centimeters) 9.2075 × 16.51
Item/No. 7
Size (inches) 3 3/4 × 6 3/4
Size (centimeters) 9.525 × 16.145
Item/No. 7 3/4
Size (inches) 3 7/8 × 7 1/2
Size (centimeters) 9.8425 × 19.05
Item/No. 8 5/8
Size (inches) 3 5/8 × 8 7/8
Size (centimeters) 9.2075 × 21.9075
Item/No. 9
Size (inches) 3 7/8 × 8 7/8
Size (centimeters) 9.8425 × 22.5425
Item/No. 10
Size (inches) 4 1/8 × 9 1/2
Size (centimeters) 10.4775 × 24.13
Item/No. 11
Size (inches) 4 1/2 × 10 3/8
Size (centimeters) 11.43 × 26.3525
Item/No. 12
Size (inches) 4 3/4 × 11
Size (centimeters) 12.065 × 27.94
Item/No. 14
Size (inches) 5 × 11 1/2
Size (centimeters) 12.7 × 29.21

WINDOW SIZE AND POSITION (UNITED STATES)

Window size 4 3/4 × 1 1/8 inches (120.65 × 28.5 mm). Position 7/8 inch (22.2 mm) from left, 5/8 inch (15.87 mm) from bottom. Size 8 5/8 inches (219.0 mm) is 5/8 inch (15.87 mm) from left, 13/16 inches (20.6 mm) from bottom.

WINDOW (CANADA)

Item/No. 8
Size (inches) 3 5/8 × 6 1/2
Size (millimeters) 92.075 × 165.1
Item/No. Banker’s Check
Size (inches) 3 5/8 × 7 7/8
Size (millimeters) 92.075 × 200.025
Item/No. Check
Size (inches) 3 5/8 × 8 5/8
Size (millimeters) 92.075 × 219.075
Item/No. No. 8 1/2
Size (inches) 3 3/4 × 6 3/4
Size (millimeters) 95.25 × 161.45
Item/No. Large Check
Size (inches) 3 3/4 × 8 3/4
Size (millimeters) 95.25 × 222.25
Item/No. Tu Fold
Size (inches) 4 × 7 1/2
Size (millimeters) 101.6 × 190.5
Item/No. No. 9
Size (inches) 4 × 9
Size (millimeters) 101.6 × 228.6
Item/No. T-4
Size (inches) 4 1/8 × 9
Size (millimeters) 104.775 × 228.6
Item/No. No. 10
Size (inches) 4 1/8 × 9 1/2
Size (millimeters) 104.775 × 241.3
Item/No. Broker Window
Size (inches) 4 1/8 × 9 1/2
Size (millimeters) 104.775 × 241.3
Item/No. No. 11
Size (inches) 4 1/2 × 9 5/8
Size (millimeters) 114.3 × 244.475

REMITTANCE (UNITED STATES)

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Large flap can be printed to contain any message. Used for coupons, credit information, applications, statements, etc.

Item/No. 6 1/4
Size (inches) 3 1/2 × 6 (3 3/8 flap)
Size (centimeters) 8.89 × 15.24 (7.9375 flap)
Item/No. 6 1/2
Size (inches) 3 1/2 × 6 1/4 (3 3/8 flap)
Size (centimeters) 8.89 × 15.5575 (8.5725 flap)
Item/No. 6 3/4
Size (inches) 3 5/8 × 6 1/2 (3 1/2 flap)
Size (centimeters) 9.2075 × 16.51 (8.89 flap)
Item/No. 9
Size (inches) 3 7/8 × 8 7/8
Size (centimeters) 9.8425 × 22.5425

POLICY (UNITED STATES)

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Primarily used for insurance policies. Also used to hold bonds, mortgages, and other legal papers.

Item/No. 9
Size (inches) 4 × 9
Size (millimeters) 101.6 × 228.6
Item/No. 10
Size (inches) 4 1/8 × 9 1/2
Size (millimeters) 104.775 × 241.3
Item/No. 11
Size (inches) 4 1/2 × 10 3/8
Size (millimeters) 114.3 × 263.25
Item/No. 12
Size (inches) 4 3/4 × 10 7/8
Size (millimeters) 276.225 × 276.2
Item/No. 14
Size (inches) 5 × 11 1/2
Size (millimeters) 127 × 292.1

CATALOG (UNITED STATES)

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Open-end style. Wide seams with heavy gummed flaps provide good protection for mail handling of catalogs, magazines, reports, etc.

Item/No. 1
Size (inches) 6 × 9
Size (millimeters) 152.4 × 228.6
Item/No. 1 3/4
Size (inches) 6 1/2 × 9 1/2
Size (millimeters) 165.1 × 241.3
Item/No. 2
Size (inches) 6 1/2 × 10
Size (millimeters) 165.1 × 254
Item/No. 3
Size (inches) 7 × 10
Size (millimeters) 177.8 × 254
Item/No. 6
Size (inches) 7 1/2 × 10 1/2
Size (millimeters) 190.5 × 266.7
Item/No. 7
Size (inches) 8 × 11
Size (millimeters) 203.2 × 279.4
Item/No. 8
Size (inches) 8 1/4 × 11 1/4
Size (millimeters) 209.55 × 285.75
Item/No. 9 1/2
Size (inches) 8 1/2 × 10 1/2
Size (millimeters) 215.9 × 266.7
Item/No. 9 3/4
Size (inches) 8 3/4 × 11 1/4
Size (millimeters) 222.25 × 285.75
Item/No. 10 1/2
Size (inches) 9 × 12
Size (millimeters) 228.6 × 304.8
Item/No. 12 1/2
Size (inches) 9 1/2 × 12 1/2
Size (millimeters) 241.3 × 317.5
Item/No. 13 1/2
Size (inches) 10 × 13
Size (millimeters) 254 × 330.2
Item/No. 14 1/4
Size (inches) 11 1/4 × 14 1/4
Size (millimeters) 285.75 × 361.95
Item/No. 14 1/2
Size (inches) 11 1/2 × 14 1/2
Size (millimeters) 292.1 × 368.3

METAL CLASP (UNITED STATES)

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Strong and durable. Ideal for mailing bulky papers and heavy publications. Can be opened and closed many times.

Item/No. 0
Size (inches) 2 1/2 × 4 × 1/4
Size (millimeters) 63.5 × 104.775
Item/No. 5
Size (inches) 3 1/8 × 5 1/2
Size (millimeters) 79.375 × 139.7
Item/No. 10
Size (inches) 3 3/8 × 6
Size (millimeters) 85.725 × 152.4
Item/No. 11
Size (inches) 4 1/2 × 10 3/8
Size (millimeters) 114.3 × 263.525
Item/No. 14
Size (inches) 5 × 11 1/2
Size (millimeters) 127 × 292.1
Item/No. 15
Size (inches) 4 × 6 3/8
Size (millimeters) 101.6 × 161.925
Item/No. 25
Size (inches) 4 5/8 × 6 3/4
Size (millimeters) 117.474 × 171.45
Item/No. 35
Size (inches) 5 × 7 1/2
Size (millimeters) 127 × 190.5
Item/No. 50
Size (inches) 5 1/2 × 8 1/4
Size (millimeters) 139.7 × 209.55
Item/No. 55
Size (inches) 6 × 9
Size (millimeters) 152.4 × 228.6
Item/No. 63
Size (inches) 6 1/2 × 9 1/2
Size (millimeters) 165.1 × 241.3
Item/No. 68
Size (inches) 7 × 10
Size (millimeters) 177.8 × 254
Item/No. 75
Size (inches) 7 1/2 × 10
Size (millimeters) 190.5 × 254
Item/No. 80
Size (inches) 8 × 11
Size (millimeters) 203.2 × 279.4
Item/No. 83
Size (inches) 8 1/2 × 11 1/2
Size (millimeters) 215.9 × 292.1
Item/No. 87
Size (inches) 8 3/4 × 11 1/4
Size (millimeters) 222.25 × 285.75
Item/No. 90
Size (inches) 9 × 12
Size (millimeters) 228.6 × 304.8
Item/No. 93
Size (inches) 9 1/2 × 12 1/2
Size (millimeters) 241.3 × 317.5
Item/No. 94
Size (inches) 9 1/4 × 14 1/2
Size (millimeters) 234.95 × 368.3
Item/No. 95
Size (inches) 10 × 12
Size (millimeters) 254 × 304.8
Item/No. 97
Size (inches) 10 × 13
Size (millimeters) 254 × 330.2
Item/No. 98
Size (inches) 10 × 15
Size (millimeters) 254 × 381
Item/No. 105
Size (inches) 11 1/2 × 14 1/2
Size (millimeters) 279.4 × 368.3
Item/No. 110
Size (inches) 12 × 15 1/2
Size (millimeters) 304.8 × 393.7

ANNOUNCEMENT OR A-STYLE

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Made for use with a wide range of matching text and cover papers. May also have deckle (ragged cut) edge and flaps.

Item/No. A-2
Size (inches) 4 3/8 × 5 3/4
Size (millimeters) 111.125 × 146.05
Item/No. A-6
Size (inches) 4 3/4 × 6 1/2
Size (millimeters) 120.65 × 165.1
Item/No. A-7
Size (inches) 5 1/4 × 7 1/4
Size (millimeters) 133.35 × 184.15
Item/No. A-8
Size (inches) 5 1/2 × 8 1/8
Size (millimeters) 139.7 × 206.375
Item/No. A-10
Size (inches) 6 × 9 1/2
Size (millimeters) 152.4 × 241.3
Item/No. A-Long
Size (inches) 3 7/8 × 8 7/8
Size (millimeters) 98.425 × 225.425

WALLET FLAP

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Mostly used by banks or investment firms for mailing statements and other documents. Deep flap and extra wide gummed area offer protection to the contents.

Item/No. 10
Size (inches) 4 1/8 × 9 1/2
Size (millimeters) 104.775 × 241.3
Item/No. 11
Size (inches) 4 1/2 × 10 3/8
Size (millimeters) 114.3 × 263.525
Item/No. 12
Size (inches) 4 3/4 × 11
Size (millimeters) 120.65 × 279.4
Item/No. 14
Size (inches) 5 × 11 1/2
Size (millimeters) 127 × 292.1
Item/No. 16
Size (inches) 6 × 12
Size (millimeters) 1524 × 304.8

BUSINESS ANNOUNCEMENT AND BARONIAL

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Formal envelopes with deep, pointed flaps. Widely used for invitations, formal announcements, greeting, and social cards.

Item/No. Gladstone
Size (inches) 3 9/16 × 5 9/16
Size (millimeters) 90.500 × 141.300
Item/No. 4 Baronial
Size (inches) 3 5/8 × 5 1/8
Size (millimeters) 92.075 × 130.175
Item/No. 5 Baronial
Size (inches) 4 1/8 × 5 1/8
Size (millimeters) 104.775 × 130.175
Item/No. 5 1/4 Baronial
Size (inches) 4 1/4 × 5 1/4
Size (millimeters) 107.95 × 133.35
Item/No. 53
Size (inches) 4 1/8 × 6 1/4
Size (millimeters) 104.775 × 158.75
Item/No. 5 1/2 Baronial
Size (inches) 4 3/8 × 5 5/8
Size (millimeters) 111.125 × 142.875
Item/No. 6 Baronial
Size (inches) 5 × 6 1/4
Size (millimeters) 127 × 158.75
Item/No. 110
Size (inches) 5 × 7 1/4
Size (millimeters) 127 × 180.975
Item/No. Lee
Size (inches) 5 1/4 × 7 1/4
Size (millimeters) 133.35 × 184.15
Item/No. 137
Size (inches) 5 1/2 × 8 1/2
Size (millimeters) 139.7 × 215.9

COIN

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Used for paper currency as well as coins by banks and corporations.

Item/No. 00
Size (inches) 1 11/16 × 2 3/4
Size (millimeters) 42.875 × 69.85
Item/No. 1
Size (inches) 2 1/4 × 3 1/2
Size (millimeters) 57.15 × 88.9
Item/No. 3
Size (inches) 2 1/2 × 4 1/4
Size (millimeters) 63.5 × 107.95
Item/No. 4
Size (inches) 3 × 4 1/2
Size (millimeters) 76.2 × 114.3
Item/No. 5
Size (inches) 2 7/8 × 5 1/4
Size (millimeters) 73.025 × 133.35
Item/No. 5 1/2
Size (inches) 3 1/4 × 5 1/2
Size (millimeters) 88.9 × 139.7
Item/No. 6
Size (inches) 3 3/8 × 6
Size (millimeters) 85.725 × 152.4
Item/No. 7
Size (inches) 3 1/2 × 6 1/2
Size (millimeters) 88.9 × 165.1

INTERNATIONAL ENVELOPE SIZES

International, or ISO, envelope sizes are based on folding A4 (210 × 297 mm, letterhead sized) paper into an envelope. Other sizes and how they fit when folded into the various ISO envelope sizes are shown below.

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An A4 folded twice into thirds fits in a DL envelope.

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An A4 folded once fits in a C5 envelope.

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An A5 folded once fits in a C6 envelope.

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An A5 folded once fits in a DL envelope.

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An A4 folded twice into quarters fits in a C6 envelope.

PRINTING CONSIDERATIONS FOR ENVELOPES

• Paper mills and commercial printers rely on envelope converters to cut, fold, glue, and assemble envelopes. Envelopes are either premade by an envelope converter and sold by paper distributors as a product made from a mill’s writing and text papers, or they are custom made by envelope converters from paper after it has been printed. Premade envelopes are less expensive than converting from flat sheets.

• Envelopes printed in four color, printed on the inside or covered entirely with exterior graphics need to be printed before they are converted into envelopes.

• Embossing or engraving will show through on the opposite side of a premade envelope, unless the tecnique is confined to the envelope flap.

It is best to engrave or emboss before the envelope is converted.

• Printing, engraving, or embossing envelopes before conversion is more expensive and time consuming and not appropriate for small runs. However, if you plan to produce a quantity of 5,000 or more, printing before conversion may be within your budget. Anticipate at least three weeks for envelope conversion and check with your vendor to find out exactly what the time frame will be.

• When printing on premade envelopes, confine graphics and return address information to the upper-left corner of the envelope. Postal regulations require that the face of the envelope be left blank for address and postal information. A 3/8-inch (9.525 mm) allowance also needs to be made at the envelope’s edges to accommodate press grippers.

Consult the following chart for standard ISO envelope sizes:

Size C3
In millimeters 324 × 458
Approximate inches 12.76 × 18.03
Size B4
In millimeters 250 × 353
Approximate inches 9.84 × 13.89
Size C4
In millimeters 229 × 324
Approximate inches 9.01 × 12.76
Size B5
In millimeters 176 × 250
Approximate inches 6.93 × 9.84
Size C5
In millimeters 162 × 229
Approximate inches 6.38 × 9.01
Size B6/C4
In millimeters 125 × 324
Approximate inches 4.92 × 12.75
Size B6
In millimeters 125 × 176
Approximate inches 4.92 × 6.92
Size C6
In millimeters 114 × 162
Approximate inches 4.49 × 6.38
Size DL
In millimeters 110 × 220
Approximate inches 4.33 × 8.66
Size C7/C6
In millimeters 81 × 162
Approximate inches 3.19 × 6.38
Size C7
In millimeters 81 × 114
Approximate inches 3.19 × 4.49

POCKET FOLDER STYLES

This two-pocket folder with glued flaps is an economical choice suitable for lightweight inserts, such as sample sheets or small brochures. It can be easily adapted to a one pocket configuration by eliminating one of the flaps. The business card slot can also be deleted if it isn’t necessary. For template see page 94

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This three-pocket configuration folds to the same 9” × 12” (228.6 x 304.8 mm) size as the two-pocket configuration but opens to reveal an additional pocket. The folder features glued flaps at either end and an unglued flap on the center panel. For template see page 95

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Square flaps can accommodate more inserts and bulkier documents than standard pocket folders. They work especially well for magazine media kits. Be sure to use heavy or laminated cover stock to achieve the necessary rigidity. For template see page 96

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The following pocket folder templates are printed at 1/4 scale. Enlarge them by 400% when scanning to bring them up to their actual size.

Template: Standard Two-Pocket Folder

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Template: Three-Pocket Folder

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Template: Two-Pocket Folder with Box Side Flaps

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This single-pocket folder has slots to hold two types of room keys. It folds to fit in a jacket pocket or purse.

Template: Single-Pocket Room Key Folder

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PRINTING CONSIDERATIONS FOR POCKET FOLDERS

Pocket folders offer a means of containing materials that will immediately add polish and professionalism to a presentation. However, they present some unique planning and production challenges.

• Pick a folder style and size that is suitable for your inserts. It’s common to plan a folder with more or larger pockets than necessary with the assumption that too much space is better than not enough. However, pockets that are too large for their inserts will allow folder materials to move around, resulting in a messy presentation.

• For a sturdy folder, select a cover stock with a basis weight that is between 100 and 120 lb. (270 gsm and 325 gsm). Have a paper dummy made to determine if the stock you’ve chosen for your pocket folder will be suitable for the inserts.

• Box pocket folders and those with three panels often require hand assembly, a factor that will add time and expense to your job. Take this into consideration when determining the size and style of a folder.

• Most commercial printers have dies for pocket folders on hand, or use a vendor with a selection from which to choose. To save time and money, check to find out what size and pocket configurations are available before you start to design.

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