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Introduction to Finishing: Mailing

Introduction to Finishing: Mailing

Mailing 101 – Episode Summary

In this mail-focused episode of The Print University, Ryan McAbee and Pat McGrew dive deep into the specialized world of mailing as a finishing process. Ideal for teams building printing industry training programs for new employees, bindery equipment training courses, or offering outsourced training for print production staff, this session provides a comprehensive look at the equipment, regulations, and best practices involved in preparing print for postal delivery.

Mailing is more than inserting into envelopes—it’s a complex, regulated finishing operation involving cutting, folding, perforating, inserting, sealing, addressing, coding, franking, and sorting. The episode covers U.S. and international mailing standards, weight limits, ZIP code-based sorting strategies, and technologies like file-based processing (MRDF) and intelligent mail barcodes (IMB).

Pat and Ryan explore automation tools that determine envelope size, insert combinations, and postage application—franked, printed, or stamped. They also explain co-mingling and householding strategies for efficient mailing, and how regulations affect envelope specs, sealing methods (wafer seals, glue lines), and processing speeds.

Real-world examples include Every Door Direct Mail (EDDM), catalogs, postcards, folded self-mailers, tabbed pieces, and security envelopes with tipped-on cards. Mailing is where design, data, substrates, and automation intersect—and when done right, it’s a powerful revenue generator and customer engagement tool.

You Will Learn:

  • Mailing-specific finishing steps: cutting, folding, perforating, inserting, sealing, coding, franking

  • USPS and international postal requirements, ZIP code sorting, and file-based processing

  • Equipment for sorting, sealing, barcode application, and weight management

  • Formats: EDDM, self-mailers, catalogs, tipped-on cards, tabbed brochures, security documents

  • Mailing strategies: co-mingling vs. householding, automation, and postage optimization

Who This Course Is For:

Production managers, mailing specialists, bindery operators, data processors, and print professionals involved in bindery equipment training courses, color management training for new hires, or preparing materials for regulatory or direct mail campaigns

Time to Watch:

Approx. 30 minutes