When Royal quotes a job, we must determine the most economical sheet size to get the most number of envelopes out with the least paper waste. How to set up an envelope can be quite a challenge, similar to a puzzle! Envelopes must be arranged in a way so that the paper breaks and all the envelopes come out the same size when the die comes down on the paper. It is very important to request an envelope layout from Royal if you are going to send in a converting job. Also equally important are “knock-outs” for ink on full coverage envelopes. In order for side seam gum and seal gum to adhere to the paper there must be no ink in between, therefore we must “knockout” that area. Royal will supply a die template with ink “knockouts”. If we do not supply you with an envelope layout* we cannot guarantee that we can complete the job properly. Royal can supply a paper layout on the exact sheet size or create a digital layout which is downloaded to a disk or emailed. Below are three different layouts, notice how they fit like pieces of a puzzle.