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Guidelines for Litho Envelope Conversion
The purpose of this guideline is to inform you of standard specifications and tolerances for the conversion of Litho printed envelopes. If you have any questions, please consult your Account Manager.
Quicklinks:
CREATIVE STAGE | Envelope Graphics and Design | Window Specifications - "Front" | Window Specifications - "Back" | Suggested Papers for Converting
PRINTING STAGE | Run Waste | Client/Printer Responsiblity
CREATIVE STAGE
 Before creating a new envelope design, it is strongly recommended that a blank of the envelope or a 1 up dieline be secured from your representative. Our most popular layouts are available as an electronic template.
Note: It is suggested that you do not use a previously printed envelope or an envelope from a competitor at the creative stage. Slight variations are difficult to detect until the actual conversion and it can be a very costly venture to repair or replace the product at the converting stage.
Envelope Graphics & Design
Envelope design and graphics should be planned around these tolerances and should take into account the following factors:
 Matching graphics from one envelope panel to another is nearly impossible
- Matching graphics from the flap to the back panels is nearly impossible
- Must plan a minimum of 1/4" bleed around each panel
- Copy should be kept away from the window area by at least 1/4" unless intended
- Plus or minus 1/16" of an inch tolerance must beallowed for in the following areas:
- Die cutting
- Folding
- Windows
Where design does not confirm to above, please be advised that variations are likely to be visually obvious.
Window Specifications - "FRONT"
 Window may be positioned within 3/8" of the perimeter of the envelope
- Showcase windows must allow a 7/8" perimeter
- Multiple window envelopes require a minimum of 1/4" between windows to allow for gumming (same for back)
- Wrap around windows to be discussed for position
Window Specifications - "BACK"
 No closer than 1-3/8" minimum from the end of the back panel of the envelope blank
- Position left and right is determined by size of side seam
- No lower than 3/8" from bottom score
- All showcase windows require 80lb. basis weight paper on sizes 6 x 9 and under, and 100lb. basis weight for envelopes larger than 6 x 9
- Wrap around windows must be discussed for position
Suggested Papers for Converting Normal Mailing Envelopes
(but not limited to below)
 Jenson Satin or Gloss Coated
- Luna Gloss or Matte
- Resolve Gloss or Matte
- Euro Art Gloss or Matte
- Hikote Gloss or Matte
Recommended Minimum Basis Weight to be used:
| Envelope Size: |
Coated: |
Uncoated: |
| Up to 6x9 |
70lb. |
60lb. |
| Over 6x9 |
80lb. |
60 or 70lb. |
Note:
When
a special paper is required, we recommended that you check
with your Account Manager prior to design. We will be
glad to investigate to ensure that that the paper you
request will indeed convert into a compliant product.
PRINTING STAGE
If you are supplying printed sheets for conversion, please ensure the following guidelines are followed:
Run Waste - Normal Mailing Envelopes
| Envelope Size: |
Coated: |
| For each version less than 10M |
2,000 overs required |
| Less than 20M |
15% waste |
| Over 20M |
10% waste |
| Over 500M |
8% waste |
Complex Envelopes
(.i.e. Perfs, Multiple Windows or Large Window Envelopes)
To be discussed upon application.
Client/Printer Responsibilities
- A dieline has been secured from us
- Film complies with all specifications noted above
- When there is full coverage graphics on coated stock, check with us as to whether or not a spot/full varnish will be required
- Arrange for a full dylux proof of the full printed sheet to be made, that follows the layout provided
- Forward the full dylux proof of the full printed sheet to us or ask for your representative to come in and see the proof
- Arrange for any requested changes to be done and a new dylux proof provided
- We will sign off on the final proof for convert-ability
- Upon completion of printing, arrange for the dieline to be returned with printed stock
 ENVELOPE JOBS SHOULD NOT GO TO PRESS WITHOUT FIRST SECURING OUR SIGNATURE OF APPROVAL ON A FINAL DYLUX PROOF OF THE FULL SHEET, VOID OF ANY CHANGES.
- In order to maintain registration throughout the die cut operations, please ensure sheets are properly jogged
- Ensure pallets are properly banded and clearly identified as to contents and sheet counts
- Ensure all versions are identified by pallet
Note:
This instruction covers a wide range of specifications for envelopes. If there are any questions about an envelope, before going any further, please contact your Account Manager for clarification.
For more information, please contact us. |
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