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Envelope Design Guidlines

There are several different printing processes available to use when printing envelopes. Below is a guide to help achieve quality on your envelopes:

Offset Printing

  • Allow 1/8" minimum bleeds due to +/- 1/16" variance on envelope converting equipment.
  • Keep weight of rules to a minimum of 1/2 pt. Keep to 1 pt. in reverse areas.
  • Type can be aby point size but a minimum of 5pt. is recommended, with a 7pt. minimum in the reverse areas.
  • Screens should be 133 to 150 lpi, depending on the press equipment.
  • Standard traps are 1/4 pt.

Thermography

  • Keep screens to a 120 line screen or coarser.
  • Use a screen density that is a little lighter than what you would like on the finished product. Screens have a tendency to fill in with the thermography process and will appear a little darker than normal.

Flexography and Letterpress

  • Allow 1/8" minimum bleeds due to +/- 1/16" variance on envelope converting equipment.
  • Keep weight of rules to a minimum of 1 pt. Keep to 1 1/2 pt. in reverse areas.
  • Use a minimum of 6 pt. sans serif type for best quality. When using serif type, use a minimum of 8 pt.
  • Screens are usually 65 lpi. Keep screen densities at 40% or less for best results.
  • Halftones print alright if the original or the digital scan is good quality. Avoid duotones, tritones and gradient screens.
  • Avoid having large solids and screens in the same color - use a lighter color of ink instead of screening in the same color.
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