Envelope Printing Services

Every piece of business mail starts with an envelope. It is the first thing your recipient sees, the first thing they touch, and frequently the deciding factor in whether your letter gets opened or tossed. Yet most businesses treat envelope printing as an afterthought -- ordering whatever their office supply vendor stocks and slapping on a return address label.

That is a missed opportunity. A professionally printed envelope communicates credibility before the flap is ever lifted. It signals that you are an established organization that pays attention to details. And when you pair the right envelope size, printing method, and finishing options with a well-designed direct mail package, you create a physical experience that digital channels simply cannot replicate.

This guide covers everything you need to know about envelope printing services: the standard sizes and when to use each one, printing methods from digital to offset to thermography, custom options like windows and security tint, realistic pricing at various quantities, and how envelopes fit into larger direct mail campaigns. Whether you are mailing 500 invoices or 50,000 fundraising appeals, you will walk away knowing exactly what to specify on your next order.

What Are Envelope Printing Services?

Envelope printing services produce custom-printed envelopes for business correspondence, marketing campaigns, invoicing, donor appeals, and any other application where a plain white envelope falls short. A commercial envelope printer takes your artwork -- logo, return address, branding elements, teaser copy -- and prints it directly onto envelope stock using digital or offset presses.

The scope of what qualifies as "envelope printing" has expanded significantly in the last decade. Where businesses once ordered boxes of one-color return address envelopes and called it a day, modern digital presses can produce full-color, variable-data envelopes with unique recipient names, personalized offers, and QR codes on every piece in the run.

Here are the most common applications for printed envelopes:

• Business correspondence -- Letterhead envelopes with your logo, address, and branding for day-to-day mail
• Invoices and statements -- Window envelopes that reveal the recipient address printed on the enclosed document, eliminating the need for separate addressing
• Direct mail campaigns -- Outer envelopes with teaser copy, full-color graphics, and personalization designed to maximize open rates
• Donor and fundraising appeals -- Nonprofit reply envelopes (often with a courtesy reply FIM mark) enclosed alongside appeal letters
• Event invitations -- A7 and A2 envelopes with calligraphy-style addressing, foil accents, or thermography for a premium tactile feel
• Explanation of Benefits (EOBs) and HIPAA-regulated mail -- Security-tinted envelopes with variable data addressing, produced under strict chain-of-custody controls

The value of professional envelope printing goes beyond aesthetics. Printed envelopes run through USPS automated sorting equipment more reliably than labeled envelopes because the ink is flush with the paper surface. That means fewer rejects, fewer delays, and better deliverability across your entire mailing.

Standard Envelope Sizes

Choosing the right envelope size is not just a design decision -- it affects postage cost, automation compatibility, and whether your piece even qualifies for letter rates versus flat rates. Here are the five sizes that account for roughly 90% of all business mail.

Envelope	Dimensions	Common Uses	USPS Class
#10	4.125 x 9.5 in	Letters, invoices, statements, checks, business correspondence	Letter
6 x 9	6 x 9 in	Booklets, catalogs, multi-page inserts, brochures mailed flat	Flat
9 x 12	9 x 12 in	Full-size documents mailed unfolded, contracts, marketing kits	Flat
A7	5.25 x 7.25 in	Invitations, announcements, greeting cards, fundraising appeals	Letter
A2	4.375 x 5.75 in	RSVP cards, thank-you notes, gift enclosures	Letter

The #10: The Workhorse of Business Mail

The #10 envelope is the standard for nearly all business correspondence. It fits a letter-size sheet folded in thirds, which is why it pairs with virtually every business letter, invoice, and statement template. If you are only going to print one envelope size, this is the one.

Because the #10 falls within USPS letter-size dimensions (minimum 3.5 x 5 inches, maximum 6.125 x 11.5 inches, maximum 0.25 inches thick), it qualifies for the lowest First-Class and Marketing Mail postage rates. When printed with an Intelligent Mail barcode (IMb) and proper FIM mark, a #10 envelope qualifies for automation letter rates -- currently the cheapest way to send a piece of mail through the postal system.

6 x 9: The Flat Alternative

A 6 x 9 envelope lets you mail multi-page booklets, tri-fold brochures, or small catalogs without folding. It sits in an awkward middle ground for postage: it exceeds letter dimensions, so it mails at flat rates unless you keep it thin enough to qualify as a letter (which is rare once you add inserts). Many nonprofits and insurance companies use 6 x 9 envelopes for benefit summaries and enrollment kits.

9 x 12: Full-Size Document Mailer

When you need to mail contracts, proposals, or marketing kits without folding, the 9 x 12 is the standard. Real estate agents, legal offices, and HR departments use them daily. They always mail at flat rates, so factor that into your budget. The larger print area does give you significant real estate for branding and teaser copy.

A7 and A2: Invitation and Response Sizes

The A7 is the classic invitation envelope. It fits a 5 x 7 card and is used for event invitations, fundraising appeals, and formal announcements. The A2 is its smaller companion, sized for RSVP and response cards. Both mail at letter rates, and the "handwritten" look of a properly addressed A7 consistently outperforms standard #10 envelopes in direct mail response rate tests.

Envelope Printing Methods

The printing method you choose determines your cost per piece, color capabilities, minimum order quantity, and turnaround time. Three methods dominate commercial envelope printing, and each serves a different segment of the market.

Digital Printing (Xerox Versant, HP Indigo)

Digital envelope printing has transformed the industry. Modern production presses like the Xerox Versant print full CMYK color directly onto envelope stock at speeds of 100+ envelopes per minute, with no plates, no makeready, and no minimum quantity penalty.

Best for:

• Short runs of 250 to 5,000 envelopes
• Variable data printing (unique names, addresses, barcodes, QR codes on every piece)
• Full-color designs with photos, gradients, or bleed
• Fast turnaround (same day to 3 business days)
• A/B testing different envelope designs in the same print run

Digital printing is the only practical method for statement and invoice runs where every envelope carries a different recipient address and account number. It is also the go-to for direct mail campaigns that use personalization to boost response rates.

Offset Printing

Offset lithography remains the gold standard for long-run envelope production. The process uses aluminum plates to transfer ink to a rubber blanket, which then presses the image onto the envelope. Setup is expensive -- plates, ink mixing, and makeready typically add $200 to $500 to the job -- but the per-unit cost drops steeply at higher quantities.

Best for:

• Long runs of 5,000 to 100,000+ envelopes
• PMS (Pantone) spot colors for exact brand color matching
• One- or two-color designs where color accuracy is critical
• Annual stationery orders where you print a year's supply at once

If your brand guidelines specify a PMS color and you need absolute consistency across 25,000 envelopes, offset is the right call. The ink laydown is heavier and more opaque than digital toner, which shows on colored or textured stocks.

Thermography (Raised Ink Printing)

Thermography applies a resin powder to wet ink, then passes the envelope through a heating element that melts the powder into a raised, glossy finish. The result mimics the look and feel of engraving at a fraction of the cost.

Best for:

• Formal stationery, law firms, financial advisors, executive correspondence
• Event invitations where a tactile impression matters
• One- or two-color designs (thermography does not work well with full-color process printing)

Thermography adds $0.03 to $0.08 per envelope depending on quantity and coverage area. It is a cost-effective way to add a premium feel without the $500+ die cost of genuine engraving.

Custom Envelope Options

Standard envelope printing covers the outside of the envelope -- your logo, return address, and any design elements. But the envelope itself can be customized in dozens of ways that affect function, security, and the recipient's experience. Here are the options that matter most.

Window Envelopes

A window envelope has a die-cut opening covered by a clear glassine or polywrap panel that reveals the address block printed on the enclosed document. This eliminates the need to print the recipient's address on the envelope itself, which is why windows are standard for invoices, statements, and any variable-data correspondence.

• Single window (standard) -- One opening on the lower left front, approximately 1.125 x 4.5 inches, positioned to show a standard address block
• Double window -- A second opening on the upper left reveals your return address from the enclosed letter, eliminating pre-printed return addresses entirely
• Full-face window -- The entire front panel is replaced with clear film, exposing a full-color insert. Used for catalogs, marketing pieces, and high-impact direct mail
• Custom window placement -- Non-standard window positions for remittance envelopes, donation reply envelopes, or specialized forms

Window position matters for USPS automation. The address must be visible through the window in every orientation the piece might shift to during handling. Most printers follow USPS DMM (Domestic Mail Manual) window specifications, but always confirm clearances with your mail service provider.

Security Tint

Security tint is a printed pattern -- typically a crosshatch, basket weave, or random pattern in blue or gray -- applied to the inside of the envelope. It prevents the contents from being read when the envelope is held up to light.

You need security tint whenever you mail:

• Checks or payment documents
• Financial statements, tax forms, or 1099s
• Medical Explanation of Benefits (EOBs) or HIPAA-regulated documents
• Social Security numbers or other personally identifiable information
• Insurance policy documents

Most commercial #10 envelope stock comes with security tint pre-printed. For custom orders, you can specify tint color and pattern. Some high-security applications use dual-layer tint or opaque envelope stock for additional protection.

Seal Type: Peel-and-Seal vs. Gum Flap

Gum flap (moisture-seal) is the traditional envelope closure. You moisten the adhesive strip to activate it. Gum flap envelopes are the cheapest option and work well for machine inserting because the flap stays open during the inserting process and is sealed by the machine's moisture unit.

Peel-and-seal (self-seal) envelopes have a pressure-sensitive adhesive strip protected by a release liner. Peel the liner, press the flap down, and the envelope is sealed. Peel-and-seal adds $0.01 to $0.03 per envelope but eliminates the need for moisture-seal equipment -- making it the preferred choice for hand-assembled mailings and office use.

Additional Custom Options

• Colored stock -- Envelopes in branded colors (kraft, navy, red, cream) for invitations, holiday mailings, or brand differentiation. Colored stock costs 10-30% more than white.
• Custom sizes -- Non-standard dimensions for specialty applications. Requires a custom die ($150-$400 one-time cost) and usually has minimum orders of 2,500+.
• Return address printing -- Pre-printed return address on the upper left corner or back flap. Often combined with logo and branding elements.
• Courtesy reply envelopes (CRE) -- Pre-addressed envelopes enclosed for the recipient to mail back. Common in nonprofit fundraising and billing.
• Business reply envelopes (BRE) -- Postage-paid reply envelopes where the mailer pays postage only on returned pieces. Requires a USPS permit.

How Much Does Envelope Printing Cost?

Envelope printing costs depend on five variables: size, quantity, number of ink colors, custom features (windows, security tint, seal type), and printing method. Here are realistic price ranges based on current market rates from commercial printers.

Specification	Quantity	Price Range	Per Piece
#10, 1-color (return address only)	500	$80 - $150	$0.16 - $0.30
#10, 1-color (return address only)	1,000	$100 - $180	$0.10 - $0.18
#10, full-color digital	1,000	$200 - $400	$0.20 - $0.40
#10, full-color digital	5,000	$500 - $900	$0.10 - $0.18
#10 window, 1-color	1,000	$120 - $220	$0.12 - $0.22
6 x 9, full-color digital	1,000	$250 - $450	$0.25 - $0.45
9 x 12, full-color digital	500	$150 - $300	$0.30 - $0.60
9 x 12, full-color digital	1,000	$250 - $500	$0.25 - $0.50
A7, full-color digital	500	$120 - $250	$0.24 - $0.50
#10, 2-color offset	10,000	$600 - $1,000	$0.06 - $0.10

What Drives the Price Up

• Full color vs. 1-color -- Full CMYK printing typically costs 40-80% more than single-color at the same quantity
• Window envelopes -- Add $0.02 to $0.05 per piece for single window; double window adds more
• Security tint -- Adds $0.01 to $0.03 per piece if not included in the base stock
• Peel-and-seal -- Adds $0.01 to $0.03 per piece over gum flap
• Colored or specialty stock -- 10-30% premium over standard 24# white wove
• Custom die-cut -- One-time die charge of $150 to $400 for non-standard sizes or window placements

How to Reduce Your Cost Per Envelope

Order in quantity. The biggest cost lever is volume. Moving from 500 to 5,000 envelopes typically cuts your per-piece cost by 50% or more because setup costs are spread across more units.

Consolidate sizes. If you use three different envelope sizes, see if you can standardize on one or two. Fewer SKUs mean larger runs of each, which means lower unit costs.

Choose the right method for your quantity. Digital printing wins under 3,000 pieces. Offset wins above 5,000. Running 500 envelopes on an offset press wastes money on setup; running 20,000 on a digital press wastes money on toner.

Bundle with mailing services. When you combine printing and mailing with one vendor, you eliminate shipping costs between the printer and the mail house, reduce handling, and often get better pricing on both services.

Envelope Printing for Direct Mail Campaigns

In direct mail, the envelope is not packaging -- it is the first piece of your marketing. A direct mail package typically consists of an outer envelope, a letter, one or more inserts (brochure, reply card, lift note), and a reply envelope. Each component has a job. The outer envelope's job is singular and critical: get opened.

Teaser Copy: The Envelope as Billboard

Teaser copy is the text printed on the outside of a direct mail envelope designed to compel the recipient to open it. Decades of direct mail testing have shown that well-written teaser copy can increase open rates by 20-40% compared to a plain, "blind" envelope.

Effective teaser copy strategies include:

• Urgency -- "Time-Sensitive Material Enclosed" or "Response Required by March 15"
• Curiosity -- "The one thing your accountant won't tell you about 2026 taxes"
• Benefit -- "Save 30% on your commercial printing. Details inside."
• Official tone -- "Important information regarding your account" (common for insurance and financial services)
• Personalization -- "Prepared exclusively for [Name]" printed via variable data

The opposite approach -- a completely blank outer envelope with only a return address -- also works for certain audiences. This "mystery envelope" tactic performs well for B2B mail, high-net-worth donor appeals, and any audience that is conditioned to ignore marketing-looking mail.

Creating a Cohesive Mail Package

The most effective direct mail campaigns treat the envelope, letter, and inserts as a unified design system. The envelope sets a visual tone and makes a promise. The letter fulfills that promise. The inserts provide proof and a clear call to action.

For example, a nonprofit fundraising appeal might use:

• Outer envelope: A7 size, cream stock, handwriting-style font for the address, teaser reading "Your community needs you this winter"
• Letter: Personalized 2-page letter from the executive director, matching cream paper
• Insert: Photo card showing the organization's impact
• Reply envelope: #9 courtesy reply envelope with the organization's address and FIM mark

When all four pieces share a visual language -- consistent colors, typography, and messaging -- response rates climb. When the envelope looks like it came from a different organization than the letter inside, trust erodes.

Automation Requirements for Bulk Mail Rates

If you are mailing 200+ pieces at Marketing Mail rates (or 500+ at First-Class presort rates), your envelopes must meet USPS automation-compatible standards to qualify for the deepest discounts. Here is what that means in practice:

• Intelligent Mail barcode (IMb) -- A 65-bar barcode printed in the address block area that encodes the delivery point, ZIP+4, and mailer ID. This is required for all automation-rate mailings.
• Facing Identification Mark (FIM) -- A series of vertical bars printed in the upper right area of courtesy reply mail (FIM A), business reply mail (FIM C), or metered mail (FIM D). FIM marks tell USPS sorting machines which way to orient the piece.
• Clear address zone -- The address area must be free of competing text, graphics, or patterns that could confuse optical character recognition (OCR) readers.
• Machinable dimensions -- Letter-size envelopes must be between 3.5 x 5 inches and 6.125 x 11.5 inches, with uniform thickness not exceeding 0.25 inches.

Properly formatted envelopes can save $0.05 to $0.10 per piece in postage compared to non-automation rates. On a 10,000-piece mailing, that is $500 to $1,000 in postage savings -- often more than the entire cost of printing the envelopes.

This is where working with a combined print-and-mail facility pays off. When your envelope printer is also your mail service provider, they design the envelope to meet automation specs from the start, eliminating costly reprints and manual interventions at the mail house.

Why MPA for Envelope Printing

Mail Processing Associates has been printing and mailing envelopes since 1989. Here is what that means for your next project:

• Dedicated Versant envelope press -- Our Xerox Versant production press runs envelopes from #10 through 9 x 12 in full CMYK color, including variable data. It is dedicated to envelope work, so your job does not wait behind a queue of booklet or postcard runs.
• In-house inserting machines -- Pitney Bowes inserters stuff, fold, seal, and meter up to 10,000 envelopes per hour. Your printed envelopes go from press to inserter to mail tray without leaving the building.
• Print and mail under one roof -- Printing, addressing, inserting, tabbing, metering, sorting, and USPS induction all happen in our 35,000-square-foot facility in Lakeland, FL. One vendor. One point of contact. One accountable team.
• SOC 2 Type 2 certified, HIPAA compliant -- We handle statements, EOBs, tax documents, and other sensitive mailings for healthcare, financial, and insurance clients. Our facility, processes, and staff meet the compliance standards these industries require.
• Veteran-owned, operating since 1989 -- Three decades of envelope printing and mail processing means we have seen every edge case, every postal regulation change, and every "we need this by Friday" emergency. We know how to deliver.

Frequently Asked Questions

What is the minimum order for envelope printing?

Most commercial printers set minimums between 250 and 500 envelopes. Digital presses like the Xerox Versant make short runs of 250 or fewer cost-effective because there are no plates to set up. Offset printing typically requires 1,000 or more to justify the plate and makeready costs.

Can you print full-color images on envelopes?

Yes. Digital presses print full CMYK color on envelopes up to 13 x 17.7 inches, including photos, gradients, and bleed designs. You can print full-color on #10, 6 x 9, 9 x 12, and most standard sizes. Variable data printing also allows each envelope to carry a unique image, name, or offer.

What file format should I submit for envelope printing?

Submit a press-ready PDF with fonts embedded, images at 300 DPI, and colors in CMYK mode. Include 0.125 inches of bleed on any edge where color extends to the trim. Most printers also accept Adobe Illustrator (.ai) and InDesign (.indd) files with packaged links and fonts.

How long does envelope printing take?

Digital envelope printing typically ships in 3 to 5 business days after proof approval. Offset runs of 5,000 or more may take 5 to 7 business days due to plate production and drying time. Rush turnaround of 1 to 2 days is available at most commercial printers for an additional charge.

What is the difference between a window envelope and a full-face window?

A standard window envelope has a small rectangular cutout -- usually about 1.125 by 4.5 inches on the lower left -- that reveals the recipient address printed on the enclosed letter. A full-face window replaces the entire front panel with a clear polywrap or film, letting you show a full-color printed insert through the face of the envelope.

Do printed envelopes qualify for USPS automation postage rates?

Yes, as long as they meet USPS automation-compatible requirements. The envelope must have a delivery-point barcode (IMb), a Facing Identification Mark (FIM) for courtesy reply or business reply mail, and must be machinable in terms of size, thickness, and rigidity. Properly designed printed envelopes save $0.05 to $0.10 per piece compared to non-automation rates.

Can I print variable data like names and addresses on each envelope?

Yes. Digital presses handle variable data printing natively, meaning every envelope in the run can carry a unique recipient name, address, personalized message, or even a unique QR code. This is standard for statement runs, invoices, donor appeals, and personalized direct mail campaigns.

What is security tint and do I need it?

Security tint is a printed pattern on the inside of the envelope that prevents anyone from reading the contents by holding the envelope up to light. You need it whenever you mail checks, financial statements, medical EOBs, tax documents, or any correspondence containing personally identifiable information. Most business #10 envelopes include security tint by default.