ASK MOHAWK

ENVELOPE
MEASURING
MAILING
WINDOWS
PRINTING

BASICS
SIZING
DEFINITIONS
SPECIFYING
2 MOHAWKCON N EC TS.C OM
ASK MOHAWK

In an increasingly
electronic world,
people are turning to
traditional methods of
communicating when
it matters the most.
Printed collateral—something you can hold in your hand—
is tactile, impactful, permanent and infinitely more memorable
than an email, tweet or blog post. Studies show a return to
using print as an important part of the marketing mix to support
electronic campaigns, promote luxury goods, document an
event, or just surprise the prospective recipient.
And how does that recipient receive that correspondence?
Usually in an envelope, that container for everything from
bills to birthday cards. Unfortunately, it is often an afterthought
in the design process.
Think about this: a finely crafted envelope is often your first
impression. This guide is an effort to give you the information
you need to consider the envelope at the outset of a project:
to choose wisely, specify accurately and make the most of
that first impression.

1 800 THE MILL 1

ENVELOPE BASICS
OPENINGS
Envelopes can be manufactured in an almost endless number of sizes and
shapes. It is important to specify how the envelope should open for aesthetic
reasons as well as for functional considerations. Almost all envelopes stem
from two basic constructions: they are either open side or open end.
• Open end envelopes have the opening and seal flap on the short dimension
and are well-suited to hand insertion applications. Large open end envelopes
are called catalog envelopes.
• Open side envelopes have the opening and seal flap on the long dimension
and are ideal for automatic insertion applications and well-suited for hand
insertion applications.
When machine inserting envelope contents it is critical that you choose an
envelope that is compatible with the inserting equipment that will be used.
We recommend contacting your mail house prior to ordering your envelopes
to determine what construction is compatible with their machinery.
Envelopes being machine inserted usually require a shorter flap
(one to 1.75 inches).

OPEN END OPEN SIDE

OPEN END OPEN SIDE

2 MOHAWKCON N EC TS.C OM
ENVELOPE BASICS
CONSTRUCTION
PARTS OF AN ENVELOPE
SEAL GUM
SEAL FLAP

THROAT
SIDE FLAP

FACE

SHOULDER

BOTTOM FLAP

SEAM STYLES

DIAGONAL SEAMS

SIDE SEAMS

CENTER SEAM SINGLE SIDE SEAM

DIAGONAL SEAMS
SIDE SEAMS

FLAP STYLES

COMMERCIAL

POINTED

EURO FLAP

WALLET
SQUARE

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ENVELOPE BASICS
MEASURING
• Always measure an envelope with the flap at the top
• Envelope size is always stated in inches with the shortest dimension first
• The overall size is measured from the top fold to the bottom fold and
from one side fold to the other
• Flap length is measured from the top fold score line to the tip of the flap
• Seal gum is measured from the edge of the seal flap to where the gum
line stops
• Throat depth is measured from the top fold score line to the top of the
bottom flap
• Side flap is measured from the side fold to its farthest point at the
envelope center

FLAP AT TOP SHORT DIMENSION FIRST MEASURE FOLD TO FOLD

FLAP LENGTH SEAL GUM THROAT DEPTH

SIDE FLAP

4 MOHAWKCON N EC TS.C OM
ENVELOPE BASICS
PAPER + CONVERTING
Commercial and monarch envelopes are typically made from writing paper.
Announcement, baronial, booklet and catalog envelopes are typically made
from text weight paper. Current trends favor heavier, even cover weight, paper.
Check with your envelope supplier on feasibility of machine folding when
specifying heavier weight papers.
Designers can specify from a full range of brands, textures, colors, coated and
uncoated envelopes. Commodity envelopes are made from economical white
wove or kraft paper. However, the more an envelope gets away from white
wove, the better chance it has of getting noticed. When specifying envelopes
be sure to include all of the characteristics that you want and always check
with your mail house or the post office before committing to a design.
Paper for envelopes can be made from wood pulp, cotton fiber, or synthetic
substrates such as Tyvek. Sustainable choices include papers made with
postconsumer waste fiber, papers manufactured with FSC-certified fiber,
papers made carbon neutral with Verified Emissions Reduction credits,
papers made with emission-free renewable energy, papers made with
process chlorine free or elemental chlorine free pulps.
Envelopes can be purchased pre-converted—already cut, folded, and
glued into envelopes—or you can print flat sheets of paper and have them
converted after printing. Litho converting, or printing then converting, is
usually more expensive and will take more time but allows for uninterrupted
graphics and/or graphics that wrap smoothly from front to back.

1 800 THE MILL 5

ENVELOPE BASICS
GRAIN DIRECTION
A paper’s grain direction is a factor in folding and binding. For any type of
paper a fold parallel to the grain direction will always be better than one
against the grain direction.
Grain direction is determined on the paper machine. As the fibers come
together, they align in the same direction that the machine is moving. Then,
when the paper is sheeted from a paper roll, or subsequently cut down from
larger sheets, the grain will either run parallel to the long dimension of the
sheet (grain long), or to the short dimension (grain short).
In both printing and in envelope folding, the grain direction is an important
consideration for folding, registration and binding operations and can have
a noticeable effect on the quality of the envelopes being produced.
Most envelopes are straight grain. Envelopes are laid out on a sheet of paper
to maximize efficiency with the least waste. Consequently, in any given run
of envelopes there may be some finished envelopes that are short grain and
some that are long grain. This will be more noticeable in envelopes made
from papers with a linear texture.
Envelopes may also be specified as diagonal grain. Diagonal-grain cutting
results in more envelopes per sheet, however, these envelopes can be prone
to warping and may be more difficult to run through automated equipment.

S L

SHORT GRAIN LONG GRAIN DIAGONAL GRAIN

L L

S S

L L

STRAIGHT GRAIN CUTTING RESULTS IN ENVELOPES WITH VARYING GRAIN DIRECTION

6 MOHAWKCON N EC TS.C OM
ENVELOPE BASICS
CLOSURES
The standard closure for envelopes is a gum seal but many
other options exist—pressure sensitive, self adhesive,
latex, metal clasp and string and button.

GUM PRESSURE SENSITIVE SELF ADHESIVE

STRING AND BUTTON

LATEX METAL CLASP

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ENVELOPE BASICS
PRINTING
The two most common methods for printing envelopes are offset and
flexographic printing.
Offset offers the highest quality of envelope printing. It produces a clear,
well-defined image area and provides excellent ink coverage. It is effective
on many different paper surfaces from smooth and vellum to laid and felt.
Offset printing can be done before or after folding. After-fold envelopes are
printed upon completion of the folding process. Offset printing is generally
done after the envelope is folded, but envelopes can be cut from pre-printed
sheets which allows for copy to wrap around the back of the envelope.
Flexographic printing is done from polymer plates on which the image to
be printed is raised above the non-printing surface. Ink is applied to the
raised surface while the surrounding areas are lower and do not receive
ink. The inked image is then pressed directly onto the paper. High-speed
flexography equipment uses water based inks for fast drying on the
folding machine. Envelopes can be printed prior to being run through
the folding machine (before fold) or in-line on the folding machine.

DIGITAL
Increasingly new machines are being developed to digitally print envelopes.
While generally reserved for smaller quantities digital printing offers quick
turnarounds, high-resolution full-color and the opportunity for customization.

SPECIALTY PROCESSES
Letterpress printing, embossing, engraving and other specialty processes
should be done before converting so the impression doesn’t show through.
Regardless of the processes you use you should talk to your printer early in
the design process. Keep in mind that each press has different tolerances and
requirements. For instance, flaps and gum area can affect printing of solids and
window envelopes may not be able to run through high-heat digital presses.

8 MOHAWKCON N EC TS.C OM
ENVELOPE BASICS
THE INSIDE STORY
SECURITY TINTS
Inside solid or patterned security tints are a popular method for adding
privacy to check envelopes and other mail. There are many standard tint
patterns available. In place of generic tints, customized tints can also
be designed. These can include logos or messages that show through a
window. Remember that full coverage of darker ink colors may show
through the envelope paper, detracting from the envelope’s appearance.
Special patterned security tints are available upon request.

SECURITY TINT ENVELOPE

CONFETTI (STANDARD) LINEN

LINERS
Lined envelopes can make a big impression. Envelopes can be
purchased with colorful or specialty liners laminated to the inside
of the envelope. Patterned and decorative liners can also be added
to standard envelopes (pre-cut liners with adhesive).

LINED ENVELOPE

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ENVELOPE BASICS
WINDOWS
Windows can be any shape and run parallel or perpendicular to the seal flap.
Windows are generally parallel to the seal flap but other variations include
perpendicular, square, oval, pistol grip and rounded.
To ensure an accurate quote on a special window, it is advisable to scan and/
or email a drawing to inside sales. Custom window shapes can be made in any
shape and size.
When ordering window envelopes be sure to specify size, position, window
material and shape.

MEASURING A WINDOW
• Always measure a window envelope with the flap at the top
• Window size is always stated in inches with the height first, then length
• Position is stated relative to the left and bottom flaps of the envelope
A commercial flap envelope with a standard window has a 1.125 x 4.5 inch
rectangular window with rounded corners. It is positioned .875 inches from
the left fold and .5 inches from the bottom fold.

FLAP AT TOP MEASURE HEIGHT FIRST MEASURE LENGTH SECOND

POSITION TO LEFT FOLD POSITION TO BOTTOM FOLD

COMMERCIAL WINDOW BOOKLET WINDOW CATALOG WINDOW

10 MOHAWKCON N EC TS.C OM
ENVELOPE BASICS
WINDOW MATERIALS
POLY
The most popular and inexpensive patching material, slightly
opaque in appearance. Resistant to humidity, will melt in the
thermographic process or high-heat digital printing.
CLEAR
Completely transparent, but cannot withstand the heat of the
thermographic process or high-heat digital printing.
OPEN FACE OR OPEN PANEL
This type of window has no patch material added.
SPECIAL
Environmental window materials available by special order.
GLASSINE
Glassine lacks clarity and does not react well under humid conditions.
Safe for thermography, and recyclable, because it is a wood product.
HEAT RESISTANT
Recommended for thermography and digital printing.

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ENVELOPE BASICS
MAILING
The United States Postal Service (USPS) establishes regulations for the
mailing of business and personal correspondence. The Domestic Mail Manual
provides a comprehensive list of business mailing requirements including
bar coding, graphic restrictions, acceptable areas to place the address, and
mandatory unprinted zones. Order the manual or view the latest envelope
design requirements online at [Link]. While there, read or sign up for Deliver
magazine, the leading online resource for mail marketing strategies brought to
you by the USPS.
The envelope mailability template is a convenient guide to the proper ratio
of a mail piece’s length to height. It shows the minimum size of an acceptable
mailing piece and the dimensions that are subject to a surcharge for first-
or third-class pieces weighing up to one ounce. The USPS requires a height-to-
length ratio to fall between 1 to 1.3 and 1 to 2.5. Mailing pieces that are outside
these ratios will be subject to a surcharge. On this template, a standard envelope
will have an upper right corner that falls within the shaded area.

TO AVOID A SURCHARGE
• Minimum of 3.5 x 5 inches.
• Maximum of 6.125 x 11.5 inches
• Maximum thickness is .25 inches
• Aspect ratio (length divided by height) fall between 1.3 to 1 and 2.5 to 1

TOO TALL (SUBJECT TO SURCHARGE) TOO WIDE (SUBJECT TO SURCHARGE)

WITHIN RATIO

12 MOHAWKCON N EC TS.C OM
ENVELOPE BASICS
STORAGE + PACKING
Always store envelopes in a cool, dry, well-ventilated place. Store envelopes
standing on edge in closed and sealed boxes. The oldest envelopes should be
rotated and used first.

STANDARD PACKING
Commercial envelopes are packed 500 per box and 2,500 per carton.
Catalog and booklet envelopes are bulk packed 500 per carton.

1 800 THE MILL 13

14 MOHAWKCON N EC TS.C OM
ASK MOHAWK

A specifier’s guide to
standard envelope styles,
sizes and inserts.
The look, feel, and color of an envelope can improve response
rates, present a particular image, or evoke a desired emotion.
When designing an envelope consider the printing process, color,
texture, recycled content, and paper weight to eliminate show
through and minimize mailing costs, budget, deadline and if the
perception of quality is important to the intended audience.
Save time and money by using standard sizes. For best results,
the envelope should be at least .25 inches longer than the longest
insert. Recommended clearance from top to bottom is no less
than .25 inches.
When having an envelope quoted, remember to specify paper
grade, finish, shade, basis weight, size, flap opening, seam
construction, delivery date, quantity, packaging requirements,
and any special requests such as windows, non-standard glue
placement or printing type and location.
See our handy specification check list in the inside back
cover pocket.

1 800 THE MILL 15

COMMERCIAL FLAP
For a variety of business and personal
correspondence, including invoices, statements,
stationery, and direct mailings.
ENVELOPE SIZE ENCLOSURE

6 1/4 3.5 x 6 3.25 x 5.75

COMMERCIAL FLAP
6 3/4 3.625 x 6.5 3.5 x 6.25
8 5/8 3.625 x 8.625 3.5 x 8.325
7 3.75 x 6.75 3.5 x 6.5
7 3/4 3.875 x 7.5 3.75 x 7.25
monarch 3.875 x 7.5 3.75 x 7.25
MONARCH POINTED FLAP
9 3.875 x 8.875 3.75 x 8.625
10 4.125 x 9.5 4 x 9.25
11 4.5 x 10.375 4.25 x 10.125
12 4.75 x 11 4.5 x 10.75
14 5 x 11.5 4.75 x 11.25 COMMERCIAL WINDOW

EURO FLAP
The modern choice for stationery and cards features
a distinctive deep flap with a rounded tip.
ENVELOPE SIZE ENCLOSURE

4 baronial 3.625 x 5.125 3.5 x 4.875

A2 4.375 x 5.75 4.25 x 5.5 SQUARE EURO FLAP

A6 4.75 x 6.5 4.625 x 6.25

A7 5.25 x 7.25 5.125 x 7
5 1/2 5.5 x 5.5 5.25 x 5.25
A8 5.5 x 8.125 5.375 x 7.875
A9 5.75 x 8.75 5.5 x 8.5 BARONIAL EURO FLAP

SQUARE FLAP
Contemporary flap style that adds a touch of elegance
to any business correspondence. Particularly
popular as part of an executive stationery suite.
ENVELOPE SIZE ENCLOSURE

monarch 3.875 x 7.5 3.75 x 7.25

9 3.875 x 8.875 3.75 x 8.625
10 4.125 x 9.5 4 x 9.25 SQUARE FLAP

16 MOHAWKCON N EC TS.C OM
A-STYLE ANNOUNCEMENT
For invitations, notecards, small booklets, and promotional
pieces and, more recently, for distinctive business stationery.
This style envelope is enhanced by the use of text paper.
ENVELOPE SIZE ENCLOSURE

A2 4.375 x 5.75 4.25 x 5.5

A6 4.75 x 6.5 4.625 x 6.25
A7 5.25 x 7.25 5.125 x 7
A8 5.5 x 8.125 5.375 x 7.875
A9 5.75 x 8.75 5.625 x 8.625
A10 6 x 9.5 5.875 x 9.25 A-STYLE

MACHINE INSERTABLE
A-style envelope that will be mechanically inserted. Has
a shorter flap, like a booklet style envelope. Normally used
for bulk mail and direct marketing campaigns.
We cannot guarantee that our envelopes will work on a
specific inserter due to the number and variety of different
inserters on the market. We suggest that you request
samples for testing.
ENVELOPE SIZE ENCLOSURE

A2 4.375 x 5.75 4.25 x 5.5

A6 4.75 x 6.5 4.625 x 6.25
A7 5.25 x 7.25 5.125 x 7
A8 5.5 x 8.125 5.375 x 7.875
A9 5.75 x 8.75 5.625 x 8.625
A10 6 x 9.5 5.875 x 9.25 MACHINE INSERTABLE

BARONIALS
Deep pointed flap used for formal
announcements and invitations.
ENVELOPE SIZE ENCLOSURE

4 3.625 x 5.125 3.5 x 4.875

5 4.125 x 5.625 4 x 5.25
5 1/2 4.375 x 5.75 4.25 x 5.325 comparable to A2
6 4.75 x 6.5 4.625 x 6.25 comparable to A6
lee 5.25 x 7.25 5.125 x 7 comparable to A7
8 5.75 x 8 5.625 x 7.75 BARONIAL

1 800 THE MILL 17

SQUARE
Square flap and side seam construction for printing
uninterrupted by seams. Requires a surcharge for mailing.
ENVELOPE SIZE ENCLOSURE

5 5x5 4.75 x 4.75

5 1/2 5.5 x 5.5 5.25 x 5.25
6 6x6 5.75 x 5.75
6 1/2 6.5 x 6.5 6.25 x 6.25
7 7x7 6.75 x 6.75
7 1/2 7.5 x 7.5 7.25 x 7.25
8 8x8 7.75 x 7.75
8 1/2 8.5 x 8.5 8.25 x 8.25
9 9x9 8.75 x 8.75
9 1/2 9.5 x 9.5 9.25 x 9.25
13 1/2 13.5 x 13.5 13.25 x 13.25 SQUARE

BOOKLET
For annual reports, brochures, sales literature, and
a variety of printed material. Can be used in volume
mailings processed by inserting and sealing equipment.
ENVELOPE SIZE ENCLOSURE

4 3/4 x 6 1/2 4.75 x 6.5 4.5 x 6

5 1/2 x 7 1/2 5.5 x 7.5 5.25 x 7
5 1/2 x 8 1/8 5.5 x 8.125 5.25 x 7.625
5 3/4 x 8 7/8 5.75 x 8.875 5.5 x 8.325
6 x 9  6x9 5.75 x 8.5
BOOKLET
6 x 9 1/2 6 x 9.5 5.75 x 9
6 1/2 x 9 1/2 6.5 x 9.5 6.25 x 9
7 x 10 7 x 10 6.75 x 9.5
7 1/2 x 10 1/2 7.5 x 10.5 7.25 x 10
8 3/4 x 11 1/2 8.75 x 11.5 8.5 x 11
9 x 12 9 x 12 8.75 x 11.5
9 1/2 x 12 5/8 9.5 x 12.625 9.25 x 12.125
10 x 13 10 x 13 9.75 x 12.5 BOOKLET WINDOW

18 MOHAWKCON N EC TS.C OM
CATALOG
For large document mailings including magazines,
catalogs, sales literature, and annual reports. The
heavily gummed flap offers protection for heavy
enclosures. Catalogs, in most cases, cannot be processed
through inserting or laser printing equipment.
ENVELOPE SIZE ENCLOSURE

5x5 5x5 4.75 x 4.75 CATALOG

6x9 6x9 5.75 x 8.5
6 1/2 x 9 1/2 6.5 x 9.5 6.25 x 9
7 1/2 x 10 1/2 7.5 x 10.5 7.25 x 10
9 x 12 9 x 12 8.75 x 11.5
10 x 13 10 x 13 9.75 x 12.5
10 x 15 10 x 15 9.75 x 14.5
12 x 15 1/2 12 x 15.5 11.75 x 15 CATALOG WINDOW

POLICY / COIN
Center seam with open end construction.
ENVELOPE SIZE ENCLOSURE

5 1/2 coin 3.125 x 5.5 2.875 x 5.25

7 coin 3.5 x 6.5 3.25 x 6.25
10 policy 4.125 x 9.5 3.875 x 9.25 POLICY / COIN

REMITTANCE
Open side, side seam envelope with a large remittance flap.
ENVELOPE SIZE ENCLOSURE

6 1/4 3.5 x 6 3.25 x 5.75

6 3/4 3.625 x 6.5 3.5 x 6.25
9 3.875 x 8.875 3.75 x 8.625 REMITTANCE

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GLOSSARY OF ENVELOPE TERMS
A-STYLE ENVELOPE BUSINESS RETURN ENVELOPE
Announcement style, open side An envelope with a pre-printed
envelope with double side seam return address but no postage.
construction and a square flap.
CATALOG ENVELOPE
BACK GUM An open end, center seam envelope
Also referred to as seam gum. The with the seal flap on the short end.
adhesive used to seal the seam
CENTER SEAM
on the back of the envelope.
The permanent seam that joins
BANDING the two side flaps together at
A counting method in which a paper or the center of the envelope.
plastic band is placed around a specific
CLOSED FACE
number of envelopes. Most commonly
used for greeting card envelopes. Also known as a regular envelope,
an envelope with no window. The
BANKERS FLAP most common envelope format.
A rectangular seal flap with rounded
CLOSURES
corners. Also known as a wallet flap.
The method of securing the seal flap
BARONIAL to the back of the envelope such as seal
Mostly used for announcements and gum, string-and-button, metal clasp.
greeting cards, this envelope style has a
COIN ENVELOPE
large pointed flap and diagonal seams.
A small open end envelope used for small
BASIS WEIGHT items such as coins, jewelry or parts.
Weighing 500 sheets of any grade of
COMMERCIAL STYLE
paper in its standard basic size will
determine its basis weight. In other Open side envelope with diagonal
words, 500 sheets of 17 x 22 24-pound or double side seam with a
bond will weigh 24 pounds. The standard commercial style flap.
basic size for writing papers is 17 x 22, COMMODITY ENVELOPE
text is 25 x 38, and cover is 20 x 26. Mass produced, value priced, standard
BLEED
sized envelopes made from white
When the printed image extends wove or brown, or gray, kraft paper.
beyond the fold of an envelope or CONVERTING
off the edge of an envelope blank The process of manufacturing an
BOOKLET ENVELOPE
envelope from parent-sized sheets
An open sided envelope which of paper.
seals on the long side. CORNER CARD

BOTTOM FLAP
The printed return address in
That portion of the envelope folded upper left hand corner.
up and sealed along the edges of the CROSS BACK
side flaps to form the pocket. The style of envelope, which when
BANG TAIL
folded, has the seams diagonally across
An open side envelope with a perforated the back of the envelope. Sometimes
tail of paper attached to the back flap. abbreviated C/B. See also diagonal seam.
DECKLE EDGE
BUSINESS REPLY ENVELOPE (BRE)
A pre-addressed envelope with a first The unfinished rough edge on hand-
class permit and return address in which made and machine-made papers used
the original sender pays for its return. to decorate the flap of an envelope.

20 MOHAWKCON N EC TS.C OM
DIAGONAL GRAIN CUTTING FLUSH CUT
The grain of the paper runs diagonally An envelope with no seal flap, leaving a
across the face of the envelope, straight opening at the top of the envelope.
corner to corner. Also known as
FOIL LINED
cross grain or random cutting.
Envelopes with the inside of the flap and
DIAGONAL SEAM throat lined with a decorative colored foil
A seam running diagonally from
FOLD
the bottom fold upward toward
the throat of the envelope. Any folded edge of an envelope.
GUM
DIE
The metal form used to cut envelope Any type of adhesive or glue used in
blanks or a window opening. the manufacturing of envelopes.
GUM SLING
DIE CUT
The process of cutting envelope A term used to describe a manufacturing
blanks utilizing a die. problem caused by back gum applicators
splattering gum onto other surfaces of
DOCUMENT ENVELOPE the envelope resulting in consecutive
Sometimes referred to as legal envelopes, envelopes tacking or sticking together.
these are large, open side, double
GUM SEEPAGE
side seam outside, hex flap envelopes
produced from heavy manila or brown A term used to describe excessive
kraft stock with heavy seal gum, used application of back gum resulting in a
for mailing and storage of documents consecutive envelopes sticking together
requiring security and confidentiality. at the seam or the inside pocket of the
envelope being stuck closed at the seam.
EDGE TIGHT
HITCH-HIKER ENVELOPE
Refers to the practice of gluing the
window material all the way to the A dual-purposed envelope for use in both
edge so it does not interfere with outbound and return response mailing.
machine inserting equipment. INDICIA

EXPANSION ENVELOPE
Permit or markings on a mail
Gusseted envelope to allow piece showing that postage has
expansion for bulky items. been paid by the sender.
JOB JACKET ENVELOPE
EXPANSION SCORE
An added score along the length of a seal A large envelope in which all aspects
flap to accommodate bulky contents. of a print job are kept for reference.
Also referred to as double score. PANTONE® MATCHING SYSTEM

FIRST CLASS GREEN DIAMOND

A widely adopted ink matching color
BORDER (FCGDB)
system developed by the Pantone
Printed border identifying Company. Used to identify specific
mail as first class. colors to be used on a print job.
OPEN END
FIRST CLASS MAILER (FCM)
Any type or size of envelope with a pre- An envelope with the flap on the
printed diamond shaped border around shorter of the two dimensions.
its perimeter. The words “first class” OPEN PANEL
are normally pre-printed on the face A window envelope that does not
of the envelope but are not required. have any window patch material.
FLAPS EXTENDED OPEN SIDE
Envelopes produced and packed with An envelope with the flap on the
their flaps open and extended. longer of the two dimensions.

1 800 THE MILL 21

OPEN SIDE, DIAGONAL SEAM (OSDS) STRAIGHT GRAIN CUTTING
An open side envelope with diagonal Cutting the blanks for an envelope
seams such as a commercial #10. so the grain of the paper runs
parallel to the seams.
OPEN SIDE, SIDE SEAM (OSSS)
An open side envelope with SUBSTANCE WEIGHT
side seams such as an A6. Weighing 500 sheets of any grade of
paper in its standard basic size will
POLICY ENVELOPE
determine its substance weight. In other
A #10 through #14 size envelope with the words, 500 sheets of 17 x 22 24-pound
flap on the shorter of the two dimensions. bond will weigh 24 pounds. The
POLY standard basic size for writing papers
The most commonly used is 17 x 22, text is 25 x 38, and cover is
window patch material. 20 x 26. Also known as basis weight.

REGULAR TABBED
Any commercial envelope that A counting method for packaged
does not have a window. envelopes whereby a paper tab
is placed at specified quantities
REMITTANCE ENVELOPE within the box or carton.
A booklet or side seam style envelope
with a long wallet type seal flap covering TACKING
most of the back of the envelope. The premature activation of the seal
gum at the points where it is over
SEAL GUM the back seams of an envelope.
Any adhesive applied to the seal flap of
the envelope in order to achieve a seal. THROAT
The place between the top fold
SEAL FLAP and top of the back flap that
The flap that folds down over forms the opening.
the envelope’s opening in order to seal it.
THUMB CUT
SHOULDER A rounded opening cut through the back,
The top edge of the side flaps front, or both sides of an envelope opening
at the envelope opening. to facilitate the removal of its contents.
SIDE FLAPS TINTING
The sides of the envelope folded Patterned printing on the inside of an
to the inside and sealed along the envelope for added opacity and security.
back flap to form a pocket.
TYVEK®
SIDE SEAM A brand of synthetic paper made of
A seam that runs perpendicular flash-spun, high density polyethylene
to the envelope opening. fibers. A registered trademark of
SIDE SEAM INSIDE
Dupont, it is ultra-lightweight,
The term applied to the side tear-proof, and waterproof.
seam when it folds under the bottom flap. WALLET FLAP

SIDE SEAM OUTSIDE

A rectangular seal flap with
The term applied to the side seam rounded corners.
when it folds over the bottom flap. WINDOW

SPECIAL
An opening in the envelope
Any envelope that is not of a standard with or without a translucent patch
size, window position or paper grade. allowing the address to
show through.

22 MOHAWKCON N EC TS.C OM
Mohawk envelopes are
meticulously manufactured from
just the right paper to amplify
your message, complement
demanding graphics, and reliably
perform on envelope printing
and processing equipment.
It’s easier than ever to find paper with matching envelopes
to fit any need—from Strathmore Pure Cotton for the most
elegant stationery, to environmentally preferable Mohawk
Loop, BriteHue Ultra Pink for a fun and economical mailer
or envelopes optimized for digital printing applications.
Over 850 envelope items are stocked in Mohawk’s four
U.S. regional distribution centers providing next-day
delivery to most areas of the country through our merchant
partners. Designers, printers and end users can select
from Mohawk’s diverse palette of rich colors, fibered
shades and distinctive textures in the most popular sizes—
including commercial, A-style, baronial, foil-lined, machine
insertable, catalog and booklet envelopes. All of these
styles are complemented by a full selection of every-day
commodity envelopes to meet all of your direct mail needs.
Custom envelopes can be manufactured from any Mohawk
paper, in any standard or special size. Non-stocked envelopes
in standard sizes are part of our 3-10 day quick-turn program.
Special sizes are available for converting and shipment
within very competitive lead times. Contact your envelope
supplier or Mohawk representative for more information
or visit [Link]/products/envelopes.

1 800 THE MILL 23

MOHAWK QUALITY
We’ve die-cut a discreet “M” into an inside
seam of each Mohawk envelope made in
our Saybrook Converting Center. Holding
your envelope up to the light will reveal our
“M-notch.” It is your assurance that you
have authentic Mohawk envelopes backed
by world class service and support.

LEARN MORE
To learn more about Mohawk envelopes,
download the Mohawk Live app at the
App Store or at Google Play. Launch the
app using your mobile device, hover over
this image and prepare to be inspired!
Download envelope dielines, see complete
stocking charts, order samples of paper
and envelopes and more on the web at
[Link]/products/envelopes.

PRODUCTION
Design: Aurora Design / Niskayuna, NY
Printing: Mohawk Print Innovation Center / Albany, NY
Bindery: Fort Orange Press / Albany, NY

Covers and insert: Mohawk Superfine Smooth,

Ultrawhite 100c / 270 gsm
Text: Mohawk Superfine Smooth, Ultrawhite 80t / 118 gsm
Envelopes: Monarch / Strathmore Writing Laid Natural
White, 5 1/2 Square / Strathmore Premium Wove Smoke
Gray, A2 Machine Insertable / Mohawk Saybrook White
Wove, A2 Announcement / Mohawk Via Vellum Warm Red,
A2 Euro Flap / Mohawk Superfine Eggshell Ultrawhite,
4 Baronial / Strathmore Premium Wove Chino,
©2014 Mohawk Fine Papers Inc., Mohawk,® and the
corporate logo are proprietary trademarks of Mohawk.

24 MOHAWKCON N EC TS.C OM
3 MOHAWKCON N EC TS.C OM
465 Saratoga Street Cohoes, New York 12047 1 800 THE MILL [Link]

Mohawk is North America’s largest privately-owned

manufacturer of fine papers and envelopes which
are preferred for commercial and digital printing,
photo specialties and high-end direct mail. Mohawk
fine papers and envelopes, include the signature
brands Mohawk Superfine® and Strathmore,® as
well as proprietary treatments Inxwell® and i-Tone.®
With a culture of innovation, Mohawk’s business
model now extends beyond paper manufacturing
into new areas of growth, including digital substrates
and web-based software platforms, which connect
designers and printers to new markets.

As a leader in environmentally and socially responsible

business practices, Mohawk was the first U.S.
manufacturer of commercial printing papers to match
100% of its electricity with wind power renewable
energy credits and the first U.S. premium paper mill
to shift toward carbon neutral production. Most of
Mohawk’s portfolio of recycled papers is certified by
Green Seal and the Forest Stewardship Council (FSC).

Mohawk is a fourth-generation, family-owned and

operated business based in Cohoes, New York, with
global sales and operations located throughout North
America, Europe and Asia. For more information,
please visit [Link].

76-708970014
September 2014
ASK MOHAWK

Envelope checklist
The look, feel, and color of an envelope can
improve response rates, present a particular
image, or evoke a desired emotion. When
designing an envelope take time to consider:

GOALS AND AESTHETICS

What are your objectives?

How will your envelope stand out from the crowd?
Does the design fit in with the rest of the campaign?
Does it support your image?

PROJECT PARAMETERS

What is your production deadline?

What is your budget?
Will envelopes be stuffed by hand or on

mechanical inserting equipment?
What is your required quantity?
How should the envelopes be packaged and in what quantities?

SPECIFICATIONS

Pre-converted or custom envelope? If converting an envelope


select paper stock by paper grade, finish, shade and basis weight
Opening and flap style
Seal type
Size—make sure envelope fits contents
Construction—custom shape or non-standard construction
Window placement, size, shape and patch material
Determine graphics and number of inks
Printing process
Security tint or lining
Special finishing techniques
Postal regulations—refer to Domestic Mail Manual
Get a quote