Custom Envelope Printing in Salisbury, MD

Mail Movers produces custom printed envelopes for businesses, nonprofits, and direct mail campaigns across the Delmarva Peninsula. From standard #10 business envelopes to oversized catalog envelopes and specialty reply envelopes, we print, address, and mail — all from our Salisbury, MD facility.

Envelope Types We Print

• #10 Business Envelopes (4.125" × 9.5"): The standard for business correspondence, invoices, and direct mail letters. Available with or without window, in full-color or one-color printing.
• Window Envelopes: Single or double window configurations for letters, invoices, and statements where the address prints through the window — eliminating double-addressing and reducing production cost.
• Reply Envelopes (BRE/CRE): Business Reply Envelopes (BRE) and Courtesy Reply Envelopes (CRE) for fundraising appeals, invoice remittances, and customer response campaigns. We handle USPS BRE permit setup and compliance.
• 6×9 and 9×12 Catalog Envelopes: For multi-page documents, booklets, and oversized direct mail packages. Full-color printing available.
• Remittance Envelopes: Smaller envelopes (typically 3.5"×6" or 4"×9") inserted inside appeal letters for donor or customer payments. Commonly used in nonprofit fundraising.
• Custom Sizes: Non-standard envelope dimensions for specialty campaigns. Contact us with your specifications.

Printing Options

Mail Movers offers digital and offset printing on envelopes, with full-color capability on most sizes. Options include:

• Full-color process printing (CMYK): Logos, graphics, and promotional messaging on the outer envelope — proven to increase open rates by 15–30% compared to plain envelopes.
• One-color and two-color printing: Cost-effective for high-volume runs where full color isn't required.
• Variable data printing: Print personalized names, addresses, or messages on each envelope using our variable data printing capability.
• Teaser copy: Promotional text on the outer envelope that increases open rates. Our team can advise on effective teaser copy based on your campaign goals.

Envelope Addressing and Mailing

Mail Movers doesn't just print envelopes — we address, sort, and mail them. Our lettershop services include:

• High-speed inkjet addressing at up to 26,000 pieces per hour
• CASS-certified address processing and NCOA updates via our list cleaning service
• Intelligent Mail Barcode (IMb) application for USPS Full-Service compliance
• Presort processing for maximum postage discounts via our presort mail service
• USPS induction at the Salisbury SCF for fastest delivery

USPS Compliance for Envelopes

Envelope design must meet USPS specifications to qualify for automation postage rates. Key requirements include:

• Minimum size: 3.5" × 5"; Maximum size: 6.125" × 11.5" for letter-size rates
• Clear address zone: The delivery address must appear in a defined area with no printing or graphics in the barcode clear zone below the address
• Return address: Required in the upper left corner for First-Class mail
• Postage area: The upper right corner must be clear for the postage indicia or stamp

Mail Movers reviews every envelope design against current USPS specifications before printing. We'll flag any compliance issues before you commit to a full run — saving you the cost of reprinting or postage surcharges.

Turnaround and Minimums

Standard turnaround for envelope printing is 5–7 business days from approved artwork. Rush production is available for time-sensitive campaigns. Minimum quantities vary by envelope type and print method — contact us for specifics on your project.

Get a Quote

Mail Movers serves businesses and nonprofits in Sussex County, Delaware and Wicomico and Worcester Counties, Maryland, with pickup service and full-service production. Contact us to discuss your envelope project, or request an estimate online.

Call us at 410-749-1885 or visit our printing services page for more options.