High Die Cutting FAQ

High die cutting uses a 3″ high large steel die to cut a lift of stock 150 to 200 sheets at one time. Because of the draw of the die as it travels through the lift, the cutting register can vary 1/16″ in any direction. This is within industry standards. Bleeds must wrap 1/8″ over the fold lines. Borders must be 1/4″ away from the fold lines. Due to die cutting requirements, the sheet size and position on the sheet must follow the layout template. See our high die sheet size guide.

Yes, ECS can create a wide variety of special sizes and square envelopes. If you do not see what you are looking for on our die list, please call for layout sheet size and price.

ECS is a custom manufacturer. We do not stock any ready-made envelopes. In 14 working days or less we can make your special order, blank envelopes, windows or regulars, from our stock of 24 lb. white wove or blue inside tint stock.

The caliper of the stock must be between .0045 and .0068 for standard sizes and between .005 and .0085 for open-end catalog and large open-side booklet sizes. Best stock weights are 60# to 80# text.

Grain wrong stock curls up into the machinery causing jams, wasted stock and folding registration problems.

We can change the settings on the machine and still run grain wrong stock. The setup charge for grain wrong is $100.00 for standard sizes and $150.00 for open-end catalogs and large open-side booklets. You should also provide an additional over run for setup and waste.

An over run is required for setup and waste in the converting process. The minimum for standard sizes is 300 or 10%, whichever is greater of the finished envelope count. For open-end catalogs and large open-side booklets, allow a minimum of 400 or 10%.

Full ink coverage requires no ink or varnish in glue and gum areas. Adhesion is not guaranteed if ink or varnish is printed in those areas.

The characteristics of certain stocks and inks may result in scuffing or cracking.

Provide a blue line or sample with your purchase order which should specify the ECS die number or exact size for custom envelopes, the quantity, over run and samples needed, and shipping instructions.

Our normal production time for most jobs is 7 to 14 days after the stock arrives here. Open-end catalogs and large open-side booklets can take 7 to 14 days. For rush orders, please call in advance to schedule and for quotes on rush charges that may apply.