Australian Custom Envelope Manufacturer — Every Size, Style & Finish

Active Envelopes manufactures and custom prints envelopes for businesses, charities, banks, government agencies, lottery companies and mailing houses across Australia. Every envelope is made at our Dandenong South, Victoria facility — from 500 units to several million — with expert print-ready guidance included on every order. Browse our full range below, or get a free quote today.

Active Envelopes is an Australian Envelopes Manufacturer and Printer

Correspondence Envelopes

DL and DLX envelopes are the most widely used business envelopes in Australia. Our DL envelopes (110 × 220 mm) and DLX envelopes (120 × 235 mm) are available with standard windows, barcode windows, custom single windows, dual windows and portrait windows. Sealing options include lick & stick, peel & seal, self-seal and ungummed. All window placements are precision cut for mail house compatibility and Australia Post lodgement requirements.

Booklet Mailer Envelopes

Our booklet mailer envelopes are ideal for A4 documents, promotional material and high-volume campaign mailings. Available with or without windows, in a range of paper stocks. Suitable for both manual and machine inserting.

Common Correspondence and Booklet Mailer Sizes We Manufacture

  • DL (110 × 220 mm)
  • DLX (120 × 235 mm)
  • C5 (162 × 229 mm)
  • Maxipop (130 × 240 mm)
  • C4 Pocket (324 × 229 mm)
  • C4 Wallet (229 × 324 mm)
  • B5 Pocket (250 × 176 mm)
  • B5 Wallet (176 × 250 mm)
  • B4 Pocket (353 × 250 mm)
  • C3 Pocket (458 × 324 mm)
  • 380 × 255 mm
  • 405 × 255 mm

For oversized campaigns and marketing packs that need to stand out in the letterbox, our larger format options including

380 × 255 mm and 405 × 255 mm are available.

Donation Envelopes

Active Envelopes is a specialist manufacturer of donation envelopes for charities, not-for-profits, churches, foundations and community organisations across Australia. Our donation envelopes are fully customisable and available in a range of styles to suit your campaign format and mailing house requirements.

Donation envelope styles we manufacture:

  • Standard donation envelopes
  • Extended flap donation envelopes
  • Bangtail wallet envelopes
  • Extended flap bangtail envelopes
  • Envelopes with perforated stubs

All styles are available with full-colour offset printing to match your brand and campaign materials, in standard and bespoke sizes. We understand the specific requirements of charity mailing campaigns and work directly with your mailing house to ensure every envelope meets Australia Post lodgement specifications.

Square & Greeting Cards Envelopes

We manufacture square envelopes and greeting card envelopes for brands, retailers, greeting card companies and direct mail campaigns that need something beyond the standard correspondence range.

Square envelope sizes we manufacture:

  • 130 × 130 mm
  • 140 × 140 mm
  • 150 × 150 mm
  • 170 × 170  mm
  • 180 × 180 mm

Greeting card envelope sizes we manufacture:

  • 130 × 184 mm
  • C6 (114 × 162 mm)

All sizes are available with full-colour offset printing, a choice of paper stocks, and sealing options to suit both manual handling and machine inserting. Custom sizes outside this range are also available on request — our team will advise on feasibility and provide a quote.

Seed Envelopes

Active Envelopes manufactures seed envelopes for nurseries, garden centres, seed companies, and retail brands across Australia. Our seed envelopes are fully customisable and available in a range of sizes to suit both retail packaging and promotional campaigns.

Seed envelope styles we manufacture:

  • Standard seed envelopes
  • Gusseted seed envelopes
  • Glassine seed envelopes
  • Resealable seed envelopes
  • Envelopes with perforated tear strips

All styles are available with full-colour offset printing to showcase your branding and product information, in standard and bespoke sizes. We understand the specific requirements of seed packaging and work directly with your team to ensure every envelope meets your product and retail display needs.

All orders — whether manufactured from scratch or overprinted on existing stock — are produced in Australia with fast turnaround and expert print-ready guidance included. Our team will guide you through size selection, paper stock, print colours and artwork preparation. Print runs from 500 envelopes through to several million.

Envelope Overprinting & Printing Service

Need envelopes printed? We offer three options — overprinting on envelopes you already have or purchase separately, full-colour printing as part of our manufacturing process, and flat sheet print and make-up for complex multi-colour designs. All use offset printing for sharp, consistent results. Print runs from 500 units, with expert print-ready artwork guidance included on every order.

We offer:

  • 1–4 colour overprinting on on your own or purchased stock envelopes
  • Up to 8 colour flat sheet print and make-up
  • Full-colour branded envelopes
  • Print embellishment like foiling, spot UV, embossing and debossing
  • Security tinting for banking, government and financial correspondence
  • Pantone colour matching available on request

Paper Stocks & Materials

  • We stock and manufacture envelopes across a broad range of paper grades:
  • White offset 80–150 GSM
  • White silk 113–170 GSM
  • Brownkraft 100%-Recycled
  • Goldkraft
  • Tyvek envelopes
  • Recycled and environmentally friendly stocks

Need to match a speciality stock to your existing letterhead or stationery? Let us know the specifications and merchant and we can source and convert most specialty grades.

Window Options

Every window envelope we manufacture is precision cut for compatibility with automated inserting equipment and mail house processing.

Window options include:

  • No window
  • Standard window
  • Barcode window
  • Custom single window
  • Custom dual window
  • Portrait/picture window
  • 100% biodegradable window face

Sealing Options

Active Envelopes offers a full range of envelope sealing options to suit every mailing, campaign, and fulfilment requirement. Whether you're running a high-volume direct mail campaign across Australia or producing premium retail packaging, the right seal matters — for security, efficiency, and end-user experience. We manufacture envelopes with sealing solutions suited to both machine inserting and manual handling, giving you the flexibility to match your production line and budget.

Our sealing options include:

  • Lick & stick
  • Peel & seal
  • Self-seal (press-seal)
  • Ungummed
  • ActiveTac Reusable closure

Who We Supply

We supply custom envelopes to a wide range of Australian businesses and organisations including:

  • Charities, not-for-profits and NGOs
  • Banks and financial institutions
  • Government departments and agencies
  • Lottery companies
  • Marketing and advertising agencies
  • Mailing houses
  • Real estate agencies
  • Paper merchants and stationers
  • Greeting card companies
  • Retailers and wholesalers

If your organisation sends correspondence at volume, we have custom envelope solutions for you.