Overs, Grain Direction, Tolerances

Overs

Paper waste occurs when envelopes are converted. To insure that the required quantity of envelopes are produced, please follow the charts below when supplying papers:

(Waste Factors)

Quantity	Uncoated	C1S	C2S
0-1M	100%	150%	200%
1M - 2-1/2M	50%	75%	100%
2-1/2M - 5M	35%	50%	75%
5M - 25M	20%	25%	30%
25M - 50M	10%	15%	20%
50M Up	9%	14%	19%

(Cross grain cuts may double waste factors, particularly on OSSS Booklet and Catalog envelopes.)

Grain Direction  

Ideally, the grain direction should be perpendicular to the flap, particularly on Catalog and Booklet envelopes. The term "nested" means that the object is to get as many blanks on a sheet without regard to grain direction.

"Cross grain cuts" are those cuts that the grain direction runs horizontal to the flap. They are very difficult to fold, and in most cases may double straight grain waste factors.

"Straight grain cuts" are those cuts that the grain direction runs vertically to the flap. These cuts are easier to fold and produce the lowest waste factors.

Nested	Straight Grain	Cross Grain

Tolerances

Due to variances in cutting and converting, tolerances must be considered for envelope construction and bleed allowances. Please follow the tables below:

	Envelope Tolerances	Bleed Tolerances
Commercial Sizes up to #11	+/- 1/16"	+/- 1/8"
Commercial Size #12 and over, Catalog and Booklet	+/- 1/8"	+/- 1/4"

WARNING -- Cutting and Folding Tolerances -- avoid additional printing added after the envelope is folded. Printing the address on the back flap is suggested for multicolor logos which need multiple return addresses added after converting. Trying to register return address or additional copy after converting will result in poor registration.

Remember-- Litho converting is done with many individual cuts that will move up to 1/8" on Commercial sizes and 1/4" on larger Catalog and Booklets.