Direct Mail Envelopes — Built for High-Speed Inserting

Envelopes engineered for clean, reliable automated inserting — from a regional test drop to national campaigns of hundreds of thousands. Printed, customised and finished at our Melbourne facility.

Active Envelopes is an Australian Envelopes Manufacturer and Printer

For a mailing house, a bad batch means jammed machines, blown deadlines and wasted labour. We make direct mail envelopes that run right the first time.

What we make 

  • Sizes: DL (110×220), DLX (120×235), DLX Maxipop (130×240) for fuller packs, C5 (162×229), C5 Maxipop (162×240), C4 Pocket (324×229) for A4-flat, B5 (250×176) — plus custom.
  • Windows that won’t fight your machines: standard, barcode, custom single & dual — die-cut to align with automated inserting.
  • Sealing to suit your process: Gummed (lick & stick), Peel & Seal, Self-Seal.


Need the artwork printed on them too? See our envelope printing service.

Get a Free Quote

Why Us?

Printed in Melbourne

Artwork, proofing, printing and reprints handled at our own facility. One accountable supplier for your campaign.

Test, then scale

Run a segmented or split-test cell before you commit, then roll the winner out to national drops of hundreds of thousands to millions.

Just-in-time supply

Staged deliveries free warehouse space and cash flow; runs from 500 to several million.

Direct Mail Envelopes — Frequently Asked Questions

Formats, windows, minimums and turnaround for direct mail and machine-insert envelopes.

  • Which sizes suit direct mail campaigns?

    DL (110×220), DLX (120×235), DLX Maxipop (130×240) for fuller packs, C5 (162×229), C5 Maxipop (162×240) and C4 Pocket (324×229) for A4-flat — plus booklet mailers and custom sizes.

  • Are your windows compatible with automated inserting?

    Yes — standard, barcode and custom windows are die-cut to align with standard folding/inserting equipment to minimise jams.

  • Can I run a small test before a full campaign?

    Yes — run a segmented or split-test cell, then scale the winner to a national drop. Custom manufacture starts at 500 and scales to several million.

  • What sealing options do you offer?

    Gummed (lick & stick), Peel & Seal and Self-Seal, to suit your inserting or hand-fill process.

  • How fast is turnaround?

    Your envelopes are printed and finished at our Melbourne facility, so we keep turnaround tight and reprints quick. Exact turnaround depends on the run size and finish — we confirm a firm date with your quote, and urgent jobs can be prioritised.

  • Do you supply plain bulk as well as printed?

    Yes — plain wholesale stock, your logo overprinted, or full-colour custom-manufactured to your artwork and delivered finished. One supplier for plain and printed alike.

Request a Direct Mail Test Pack

to run on your lines