Printed Gusset Envelopes

The original and still the best in Gusset Envelope Printing. Envoprint have perfected some inventive litho print techniques, which allow near-perfect quality printing onto these.

These expandable capacity envelopes are notorious in the industry as being difficult to print onto, so many trade envelope printers out-source their gusset envelope print jobs to Envoprint. Envoprint have pioneered some inventive litho print techniques, which allow near-perfect quality printing onto these.

These expandable capacity envelopes are notorious in the industry as being difficult to print onto, so many trade envelope printers out-source their gusset envelope print jobs to Envoprint. See above images showing our quality, and get in touch directly today for further information, a quotation, or free samples.

Also known as ‘capacity envelopes’ or ‘expandable’ envelopes, printed gusset envelopes have creases or folds near the edges, allowing them to open out and take thicker, bulkier items than standard envelopes.

The paper is often thicker than average, because they typically take thicker items, 120gsm or 140gsm paper is standard for gusset envelopes, and 180gsm printed gusset envelopes are not uncommon.

The most common type of gusset envelopes is V-Bottom Gussets. These have side gusset seams that fold inwards, and a base gusset seam that folds outwards, giving a v-shaped base when partly opened out.

The flap additionally normally has a few folds to allow it to fold neatly round the thick items inside.

Another less common type of gusset envelope is a box-bottom or block-bottom gusset envelope. These have a flat base that is folded over to 1 side when stored in bulk, much like a gusseted paper bag (e.g., the type of paper bag Pharmacies often use).

Block Bottom Gusset envelopes are not so easy to print as v-bottom gusset envelopes, as the bulky base can catch on the printer, so we sometimes recommend that these are bespoke-made, using paper that has been printed prior to manufacture.

Over-Print Options

We are one of the few print companies in the UK who can litho print (at a high quality) onto DL, C5, C4, B4, and C3 Gusset Envelopes.

Other, rarer sizes, such as 10×7″ gusset envelopes are not a problem too. Our ranges of 180gsm gusset envelopes include some unusual sizes, so we can often find a size that fits your brochure, catalogue, or book very neatly, even if it’s not a standard size like A4.

Normally with over-printed gusset envelopes we recommend leaving an unprinted margin of at least 15mm right round the edges of the envelope, so that print doesn’t go over the gusset folds. The gusset seams usually fold in around 12.5mm on a 25mm capacity gusset envelope, hence the need to leave 15mm to avoid these.

If bleed print (print right to the edges) is required, or if you require printing into the gusset seams, then we recommend that these are bespoke made. When we bespoke-make gusset envelopes, we print the sheets of paper prior to the envelope manufacture, meaning that there are no restrictions to the level of ink coverage, the print can go right to the edges, or even into the envelope seams, if you take advantage of our in-house gusset envelope manufacturing service.

Whilst we can print CMYK Full Colour litho print onto white or coloured gusset envelopes, when it comes to printing onto black or very dark coloured gusset envelopes, a different approach may be needed. The only litho inks that are opaque (non-see-through) enough to show up on black gusset envelopes are silver and gold litho inks.

These show up very well and look very smart! The silver ink looks quite ‘whitish’ on the black background, and therefore is often used as a substitute for white printing onto coloured gusset envelopes. However, if a pure white print colour is required, or else a shiny metallic finish is desired, then foil printing onto gusset envelopes may be a much better solution.