Pressure seal mailers
A pressure seal mailer is a single sheet of paper printed with strips of cohesive adhesive, folded, and pressed through rollers that activate the glue. The result is a sealed, trackable mailer with no envelopes, no inserts, and no manual assembly.
How it works
Print, fold, seal. One pass.
Print with cohesive adhesive
Variable data is printed on one or both sides of the sheet. Cohesive adhesive strips are pre-coated on the stock or applied in-line.
Fold to format
The sheet is folded into a C, Z, EZ, or V configuration depending on the document and postal requirements.
Seal under pressure
Rollers apply pressure to the folded sheet. The cohesive strips bond to themselves, producing a tamper-evident seal.
Formats
Common pressure seal folds
C-fold (14-inch)
A letter-size sheet folded into three equal panels. The most common pressure seal format. Fits a #10 window reveal and presorts at letter rates.
Z-fold (14-inch)
Accordion-folded into three panels. Opens flat in one motion, which makes it a favorite for statements and notices with a tear-off remit stub.
EZ-fold (11-inch)
A shorter sheet folded once, producing a #6 or half-letter mailer. Good for short notices, payment stubs, and postcard replacements.
V-fold and bi-fold
Available for specialty layouts, checks, and secure documents where the data must be hidden behind a single fold.
Specifications
Production specs
Standard pressure seal mailers run through our production line with the specs below. Custom stocks, sizes, and finishing options are available on request.
- Paper: 20 lb bond, 24 lb bond, 60 lb offset, 80 lb opaque. Color tints and security backgrounds available.
- Cohesive adhesive strips along all four edges. Reactivated under roller pressure, no moisture or heat.
- Full variable data per piece. Name, account number, balance, barcode, MICR line, or any field in your file.
- Window reveal or full address on panel. IMB barcode printed in-line for USPS full-service tracking.
- Optional security tints, microprint, and void-if-copied backgrounds for checks and sensitive documents.
- Run sizes from 1,000 to 2 million pieces per cycle. Recurring jobs scheduled monthly or on demand.
Request a pressure seal quote
Include quantity, fold type, paper stock, and any finishing needs. We respond within one business day.