500+
From 500 envelopes manufactured to order
20 Years
Manufacturing envelopes across Australia
11+ Sizes
DL, DLX, C4, C5, C6, donation, square and more
Correspondence Envelopes — DL and DLX
DL (110 × 220 mm) and DLX (120 × 235 mm) envelopes are the most widely used business envelopes in Australia. Both sizes fit an A4 sheet folded in thirds and are compatible with high-speed inserting equipment used by mailing houses across the country.
We manufacture DL and DLX envelopes with a full range of window configurations — standard window, barcode window, custom single window, dual window, and portrait window. All windows are precision cut for Australia Post lodgement compatibility and automated inserting equipment.
Sealing options include lick & stick, peel & seal, self-seal and ungummed. Available in white offset 80–150 GSM, white silk 113–170 GSM and a range of specialty stocks.
Booklet Mailer Envelopes — Manufactured in Australia
Booklet mailer envelopes are designed for documents, promotional material, brochures and campaign inserts that are folded once or sent flat. We manufacture booklet mailers across 9 formats with or without windows, in a full range of paper stocks and sealing options, suitable for both manual handling and high-volume mailing house operations. Manufactured at our Dandenong South, Victoria facility and supplied to businesses across Australia from 500 units.
Direct Mail & Campaign Mailer — 130 × 240 mm
DLX Maxipop envelopes (130 × 240 mm) are a deeper variant of the standard DLX format, with extra depth designed specifically to carry inserts — a reply envelope, a promotional card, a ticket or a donation form — alongside the main letter or document.
The Maxipop format is the envelope of choice for Australian charity donation campaigns, lottery notification mailings, fundraising appeals and premium direct mail programmes where a standard DLX is too shallow for the full pack contents.
Who uses DLX Maxipop envelopes:
- Charities and not-for-profits running donation appeals across Australia
- Lottery companies dispatching notification and prize letters
- Marketing agencies managing direct mail campaigns for clients
- Mailing houses handling multi-insert campaign packs for Victorian, New South Wales and Queensland clients
Available with standard and custom windows, full-colour offset printing in 1 to 4 colours, and a range of sealing options including peel & seal and lick & stick. Manufactured at our Dandenong South, Victoria facility and supplied nationally from 500 units.
Not sure if Maxipop is the right format for your campaign? Call us on 03 9706 6844 and we'll advise.
A4 Half-Fold Mailer — 162 × 229 mm
C5 envelopes (162 × 229 mm) fit an A4 sheet folded in half and are one of the most widely used booklet mailer formats in Australia. The C5 is the standard envelope for invoices, account statements, insurance correspondence, payslips and formal business mail where the document needs to be folded once and dispatched at volume.
Who uses C5 envelopes:
- Banks and financial institutions sending account statements and notices across Australia
- Insurance companies dispatching policy documents and renewal notices
- Government departments sending formal correspondence to residents in Victoria, New South Wales, Queensland and nationally
- Mailing houses processing high-volume statement and invoice runs for corporate clients
- Businesses sending formal correspondence where a DL is too small and a C4 is unnecessary
Available with or without windows, in a full range of sealing options including peel & seal and lick & stick. Window positions include standard, barcode and custom placements for Australia Post lodgement compliance. Manufactured at our Dandenong South, Victoria facility and supplied nationally from 500 units.
Deep C5 Campaign Mailer — 162 × 240 mm
C5 Maxipop envelopes (162 × 240 mm) are a deeper variant of the standard C5, adding extra depth to accommodate bulkier inserts — a reply envelope, a brochure, a card or a promotional insert — alongside the main A4 document folded in half.
The C5 Maxipop is used where a standard C5 is too shallow for the full pack contents but a C4 would be unnecessarily large. It sits in the gap between the two and is particularly popular for charity campaign packs, membership renewal mailings and premium business correspondence with multiple inserts.
Who uses C5 Maxipop envelopes:
- Charities and not-for-profits running multi-insert fundraising campaigns
- Membership organisations sending renewal packs with reply envelopes enclosed
- Insurance and financial services companies dispatching multi-document correspondence
- Marketing agencies managing premium direct mail campaigns across Australia
Available with standard and custom windows, full-colour offset printing and a range of sealing options. Manufactured at our Dandenong South, Victoria facility and supplied nationally from 500 units.
A4 Flat Mailer — Short Edge Opening — 324 × 229 mm
C4 Pocket envelopes (324 × 229 mm) fit an A4 sheet flat — no folding required. The opening is on the short edge, meaning documents are loaded from the top. This is the format most commonly specified by mailing houses and fulfilment operations running automated high-volume dispatch, where the inserting equipment feeds documents in from above.
If your mailing house or fulfilment centre is handling dispatch, confirm with them whether they require pocket or wallet format — different equipment has different requirements. If you are unsure, call us and we will help you work it out.
Who uses C4 Pocket envelopes:
- Mailing houses running automated high-volume dispatch for corporate and government clients across Australia
- Government departments sending unfolded formal notices, compliance documents and legal correspondence
- Legal firms dispatching contracts, briefs and statutory documents that must not be folded
- Banks and financial institutions sending card welcome packs, terms documents and compliance notices
- Businesses across Victoria, New South Wales, Queensland and South Australia sending A4 documents flat
Available with or without windows, in a full range of paper stocks and sealing options. Manufactured at our Dandenong South, Victoria facility and supplied nationally from 500 units.
A4 Flat Mailer — Long Edge Opening — 229 × 324 mm
C4 Wallet envelopes (229 × 324 mm) fit an A4 sheet flat with the opening on the long edge — documents are slid in from the side. The wallet format is the preferred choice for manual insertion where documents are loaded by hand, and widely used for contracts, certificates, tender documents and formal correspondence that must arrive completely unfolded.
Who uses C4 Wallet envelopes:
- Legal firms, conveyancers and solicitors dispatching contracts, settlement documents and legal briefs across Victoria, New South Wales and Queensland
- Architects and engineering firms sending unfolded drawings, specifications and tender submissions
- Government agencies sending formal notices, grants correspondence and compliance documents
- Real estate agencies sending property campaign material, prospectuses and settlement documents
- Businesses sending certificates, awards and premium correspondence where presentation matters
Available with or without windows, in a full range of paper stocks and sealing options including peel & seal and lick & stick. Manufactured at our Dandenong South, Victoria facility and supplied nationally from 500 units.
B5 Document Mailer — Short Edge Opening — 250 × 176 mm
B5 Pocket envelopes (250 × 176 mm) fit a B5 document (176 × 250 mm) flat, or an A4 sheet folded to B5 size. The opening is on the short edge — documents are loaded from the top, making this format suitable for automated inserting operations where top-loading equipment is used.
B5 sits between C5 and C4 and is used where a C5 is too small for the content but a C4 would leave too much empty space inside the envelope.
Who uses B5 Pocket envelopes:
- Marketing agencies and publishers sending B5 brochures, catalogues and promotional material
- Government departments dispatching B5 format reports, booklets and formal notices
- Businesses sending promotional inserts, product catalogues and campaign material that is printed to B5 dimensions
- Mailing houses handling specialist format campaigns for clients across Australia
Available with or without windows in standard paper stocks and sealing options. Manufactured at our Dandenong South, Victoria facility and supplied nationally from 500 units.
B5 Document Mailer — Long Edge Opening — 176 × 250 mm
B5 Wallet envelopes (176 × 250 mm) fit a B5 document flat with the opening on the long edge — documents are slid in from the side. The wallet format is the preferred choice for manual insertion and smaller fulfilment runs where documents are loaded by hand rather than by automated equipment.
Who uses B5 Wallet envelopes:
- Marketing agencies and design studios sending B5 format promotional material and campaign packs
- Publishers and media companies dispatching B5 booklets, reports and subscription material
- Businesses running premium direct mail campaigns where B5 format content is part of the brand presentation
- Retailers and wholesalers sending product information, price lists and catalogue material to trade customers across Australia
Available with or without windows across a range of sealing options. Manufactured at our Dandenong South, Victoria facility and supplied nationally from 500 units.
Large Format Document Mailer — 353 × 250 mm
B4 Pocket envelopes (353 × 250 mm) are a large-format mailer for B4 documents, A3 sheets folded once, architectural plans, engineering drawings, legal submissions and oversized promotional inserts that need to be sent with minimal folding. The short-edge opening means documents are loaded from the top.
Who uses B4 Pocket envelopes:
- Architectural and engineering firms dispatching plans, drawings and specifications to clients and contractors across Australia
- Government departments sending large-format notices, maps, planning documents and compliance material
- Legal firms dispatching oversized briefs, statutory declarations and court documents
- Real estate agencies sending large-format property prospectuses, floor plans and site maps
- Marketing agencies running large-format direct mail campaigns for clients across Victoria, New South Wales and Queensland
Available in standard paper stocks with a range of sealing options. Manufactured at our Dandenong South, Victoria facility and supplied nationally from 500 units.
If you are unsure whether B4 Pocket suits your application, call us on 03 9706 6844 and we will advise.
Extra Large Format Mailer — 458 × 324 mm
C3 Pocket envelopes (458 × 324 mm) are our largest standard booklet mailer format. Designed for A3 documents sent completely flat — large-format engineering drawings, architectural plans, government tender submissions, unfolded legal documents and premium marketing packs that cannot be folded without damage or presentation loss.
C3 is a specialist size with a narrow but specific customer base. If you are sending A3 format material at volume, C3 Pocket is the correct format — there is no standard alternative that fits A3 flat.
Who uses C3 Pocket envelopes:
- Government departments and agencies dispatching large-format notices, maps, planning approvals and tender documents at state and federal level across Australia
- Architectural and engineering firms sending A3 drawings, site plans and specifications to clients and contractors
- Legal practices dispatching oversized statutory documents, court submissions and large-format briefs
- Marketing agencies running premium large-format direct mail campaigns where the oversized format is part of the impact
- Universities and research institutions dispatching certificates, large-format reports and academic correspondence
Manufactured at our Dandenong South, Victoria facility and supplied to government, professional and commercial clients across Victoria, New South Wales, Queensland, South Australia and Western Australia from 500 units.
Not a common size — if you are unsure whether C3 is right for your application, call us on 03 9706 6844 and we will advise before ordering.
Donation Envelopes for Charities and Not-for-Profits Across Australia
Active Envelopes is a specialist manufacturer of donation envelopes for charities, not-for-profits, NGOs, churches, foundations and community organisations across Australia. We understand the specific format, lodgement and mailing house requirements of charity campaigns — and we work directly with your mailing house on every order to ensure compliance with Australia Post specifications.
Our donation envelopes are fully customisable with full-colour offset printing to match your campaign materials, in standard and bespoke sizes.
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 in 1 to 4 colour offset printing, with flat sheet print and make-up available for designs requiring up to 8 colours. Manufactured at our Dandenong South, Victoria facility and shipped to charities and not-for-profits across Victoria, New South Wales, Queensland, South Australia, Western Australia and Tasmania.
Every donation envelope can be fully branded through our envelope printing service — overprinting from 100 units or full-colour offset as part of manufacturing.
Square Envelopes & Greeting Card Envelopes — Manufactured in Australia
We manufacture square envelopes and greeting card envelopes for brands, retailers, greeting card companies, wedding stationers and direct mail campaigns across Australia. All sizes are available with full-colour offset printing, a choice of paper stocks, and sealing options suitable for both manual handling and high-volume mailing operations.
Square Envelopes
Square envelopes are used for invitations, greeting cards, premium direct mail and retail packaging across Australia. We manufacture five standard square sizes and can produce custom dimensions on request.
Sizes we manufacture:
- 130 × 130 mm
- 140 × 140 mm
- 150 × 150 mm
- 160 × 160 mm
- 170 × 170 mm
Who uses square envelopes:
- Greeting card companies and gift brands supplying the Australian retail market
- Wedding stationers and invitation designers across Victoria, New South Wales and Queensland
- Marketing agencies running premium direct mail campaigns where a square format creates standout
- Retailers and wholesalers packaging gift cards and small retail products
- Brands using square envelopes as part of a premium unboxing or gift presentation experience
Custom sizes outside this range are available on request — contact us with your dimensions and we will advise on feasibility and pricing.
Greeting Card Envelopes
Greeting card envelopes are manufactured to retail display requirements with a clean finish suitable for printed branding and full-colour artwork. Compatible with standard greeting card dimensions and available with peel & seal or lick & stick closure.
Sizes we manufacture:
- C6 (114 × 162 mm)
- 130 × 184 mm
Who uses greeting card envelopes:
- Greeting card companies supplying retail chains and independent gift stores across Australia
- Gift brands and stationery retailers requiring envelopes manufactured to retail shelf display standards
- Event and wedding stationery designers across Victoria, New South Wales and Queensland
- Florists and gift businesses including envelopes with product orders and gift packaging
Manufactured at our Dandenong South, Victoria facility and supplied to greeting card companies and retailers across Australia from 500 units
Seed Envelopes — Nurseries, Garden Centres & Retail Brands Australia-Wide
Active Envelopes supplies seed envelopes for nurseries, garden centres, seed companies and retail brands across Australia. We source quality seed envelopes and can arrange full-colour printing to showcase your branding, product information and planting instructions. Available in a range of standard styles and sizes, supplied and dispatched from our Dandenong South, Victoria facility to seed companies and garden retailers across Australia.
Styles we supply:
- Standard seed envelopes
- Gusseted seed envelopes
- Glassine seed envelopes
- Resealable seed envelopes
- Envelopes with perforated tear strips
Who uses seed envelopes:
- Nurseries and garden centres packaging seeds for retail sale across Victoria, New South Wales and Queensland
- Seed companies and wholesalers distributing product nationally
- Retail brands and gift companies including seeds as part of promotional or eco-friendly product lines
- Marketing agencies running seed-based promotional campaigns where the envelope carries branding
We work directly with your team to source the right seed envelopes for your product specifications and retail display requirements, with printing and branding arranged to suit your campaign. Recycled and eco-friendly stocks are available for brands with environmental commitments.
Custom & Bespoke Envelope Sizes — Made to Order in Australia
Beyond our standard formats, Active Envelopes manufactures custom envelopes to virtually any dimension. As an Australian manufacturer — not a reseller — we produce hundreds of bespoke sizes every year for clients whose requirements fall outside the standard range.
If you have a specific size, a non-standard window position, an unusual flap configuration or a document that doesn't fit a standard envelope, we make it to order at our Dandenong South, Victoria facility.
Custom options we manufacture:
- Any size from small seed packets to oversized A3-plus mailers
- Custom window positions, shapes and sizes
- Bespoke flap styles and sealing configurations
- Specialty paper stocks matched to your existing stationery
- Full-colour offset printing on any custom format
Who orders custom sizes:
- Marketing agencies running campaigns with non-standard creative formats
- Charities and lottery companies with bespoke donation or prize pack designs
- Government and corporate clients with specific document dimensions
- Retailers and brands using envelopes as part of product packaging
Send us your specifications and we'll advise on feasibility and provide a quote.
Custom Envelopes in Australia — Frequently Asked Questions
Common questions about our envelope manufacturing service.
What is the minimum order quantity for custom envelopes?
Our minimum for custom-manufactured envelopes is 500 units. If you only need a smaller run printed onto existing or supplied stock, our envelope overprinting service starts from 100 units. Either way, print runs go up to several million.
What envelope sizes do you manufacture?
We manufacture all standard Australian sizes — including DL (110 × 220 mm), DLX (120 × 235 mm), C5 (162 × 229 mm), C6 (114 × 162 mm), Maxipop (130 × 240 mm), and C4, B5, B4 and C3 in both pocket and wallet formats — plus square and greeting card sizes. The full size list is shown above on this page.
Can you manufacture custom-size envelopes?
Yes. Alongside our standard range we manufacture bespoke sizes to your exact specifications. Send us your dimensions and we'll advise on feasibility and provide a quote.
Do you manufacture recycled or environmentally friendly envelopes?
Yes. We manufacture envelopes in 100% recycled brown kraft, gold kraft, Tyvek and a range of recycled and environmentally friendly stocks. A 100% biodegradable window face is also available for window envelopes.
Are your window envelopes compatible with mailing house inserting equipment?
Yes. Every window envelope we manufacture is precision cut for compatibility with automated inserting equipment and mail house processing, and to meet Australia Post lodgement requirements.
Do you manufacture donation envelopes for charities and not-for-profits?
Yes — we're a specialist manufacturer of donation envelopes for charities, not-for-profits, churches and community organisations across Australia. Styles include standard, extended flap, bangtail wallet, extended flap bangtail, and envelopes with perforated stubs, all available with full-colour printing.
What is the difference between a wallet and a pocket envelope?
A wallet envelope has its opening and flap along the long edge, while a pocket envelope opens on the short edge. Pocket envelopes are generally used for thicker documents and bulkier contents. We manufacture both formats across C4, B5, B4 and C3 sizes.
Where are your envelopes manufactured, and do you deliver Australia-wide?
Every envelope is manufactured at our facility in Dandenong South, Victoria — we're 100% Australian-owned. We deliver Australia-wide, including Victoria, New South Wales, Queensland, South Australia, Western Australia and Tasmania.
