Folding machine basics

Letter folders are popular for two reasons: First, its versatility allows you to find an affordable solution for different folding needs. Second, it’s easy to use. You simply place paper in the hopper, set the fold plates or program the control panel to select the type of fold, and turn the machine on. The equipment then folds the documents to your specifications and neatly moves them to a catch tray at the other end.

Paper type
The type of paper used in your folding projects can affect the type of equipment you should use:

• Size: Most low-end machines only work with 8.5” x 11” letter or 11” x 14” legal paper, so you may need specialized equipment if you work with other paper sizes.
• Weight: This refers to the thickness of the paper stock – heavier stock requires equipment strong enough to fold it properly.
• Finish: The surface of the paper you use (smooth, glossy, textured) will indicate if you need to use equipment with rollers that pull the paper into the machine (friction feed) or a vacuum that sucks the paper in (air feed).

Friction feeder vs. air feeder
Friction feeders are standard on most low-to-mid-range letter folders. They guide paper through the machine with rubber rollers. Friction feeders are inexpensive and work best for quick, low-volume folding needs. However, the constant friction between the rollers makes the mechanism wear out over time and can damage the paper. You also can’t use friction feeders for glossy or transparent paper stock, as the rollers will smudge the ink.

Letter folding equipment with air feeders uses a vacuum system that pulls the paper into the machine. It’s best for high-volume folding and working with coated or glossy paper stock. Since the suction feed prevents long-term damage to the gears, these machines last longer – but they’re much more expensive than friction feeders.

It’s common for businesses that process different quantities of mail to use both types of letter folders. A mail house or print shop, for example, can handle smaller jobs with a friction feeder machine to help preserve the life of air feeder machines for more intense folding projects.

Letter folder/inserters
If you want to further streamline your mailing process, a letter folder/inserter can do more of the work for you. These machines take folded documents, insert them into envelopes, and seal them shut. In addition, you can connect folder/inserters with other mailing equipment like postage meters and addressing equipment for a completely automated mailing solution.

Folder/inserters are slower than dedicated folders and also more expensive. If you need folder/inserters that work with different paper and envelope sizes or additional mailing inserts, you’ll pay even more.

Other types of letter folders are more application specific. Folder/pressure sealers transform paper into self mailers by folding a sheet in half and sealing the edges, which can then be torn off to reveal the contents. These machines are commonly used for such mailings as tax refunds or debit card PIN notices.

With folder/tabbers, you can select the type of fold you want and seal the back with a small sticker (like takeout menus or church bulletins).