The Whitley Printing Company

Designing for Mail

Envelope Converting Basics

Litho converting is the process that converts a flat sheet into an envelope. The sheet may have previously been printed and/or embossed, which means the creativity of the project can extend to the envelope and need not be limited by the printing capabilities of ready-made envelopes. Converting allows the designer to include large solids, custom tints, and full bleeds on a wide range of coated or uncoated stocks.

See Envelope Sizes for the dimensions for common envelope types.

Designer Tips for Successful Converting

Here are some things to consider when designing envelopes to be converted.

1. Due to envelope converting process tolerances, plan for bleeds to extend past seams and around folds by at least 3/16 inch.
2. Ideally, flaps should be perpendicular to the grain, especially on catalog and booklet envelopes.
3. The more unusual or complicated the design, the earlier you need to contact your printer to discuss the converting process. You should also check with the U.S. Postal Service to ensure your envelope design doesn’t conflict with postal regulations, as graphic elements may not interfere with the address block.
4. Don’t expect images to look perfect when printed across envelope seams. The multiple cutting, folding, and gluing processes make exact graphic registrations across seams extremely difficult.
5. Copy on converted envelopes can vary in position by as much as ⅛ inch. Avoid additional printing after the envelope is folded, as register will be difficult. If a return address must be added after conversion, consider printing it on the flap.
6. When designing a custom tint for the inside of an envelope, make sure the tint isn’t so dark that it shows through the paper once it’s converted.
7. Remember to “knock-out” the area on the envelope flap where the re-moistenable glue adhesive will be applied.