Call Now: 515-265-4091

Bindery and Finishing Mailing Services Multimedia Services Binding & Finishing Quote Binding Awards


Helpful Tips

Latest News


Bindery 1 has a large surplus of Wire-O binding elements we are offering at a *significant discount*. The Wire-O elements are 7/8” in diameter and pewter in color. If your project calls for Wire-O binding with these parameters, contact us today and *save money* on your materials costs!

Refolding Makes it Smaller and Cheaper

If you have a comment, question or suggestion for a newsletter topic, please contact us at We would love to hear from you!

The newest postal rates, unveiled May 14th, have far-reaching implications for direct marketers. The shape of a mail piece factors more heavily into the rate than before, as the dramatic increases in flat-size rates for both first-class and standard mail effectively penalizes larger pieces.

For marketers with projects in production or in storage, this could be bad news. However, refolding is one solution that can be performed on previously saddle stitched, pasted or folded products. This may allow pieces to qualify for lower postage rates, offering significant savings for medium- and high-volume projects.

Refolding Basics
Refolding is the process of folding a collated and bound piece to reduce its overall dimensions. At Bindery1, refolding can be performed inline during saddle stitching, inkjet imaging and wafer sealing to create a highly efficient production process for direct mail pieces.

Refolding can incorporate one or two folds performed either parallel or perpendicular to the spine or initial fold. For example, to achieve a 5.5” x 8.5” final size, an 8.5” x 11” piece may be folded once while an 11” x 17” piece may be folded twice (quarter-folded). To achieve a final size of 4.25” x 11”, an 11” x 17” project may be folded twice.

Planning Tips
Product Thickness Matters - Products designed for refolding should have fewer than 32 pages; stitched booklets folded parallel to the spine should have no more than 16 pages for most stock weights. Thicker products will have too much stress placed on the spine during refolding, which could compromise quality, strength and appearance. However, these are recommendations and not absolutes; please contact Bindery1 to see how we can handle your specific application.

Tabbing for Self-Mailers – Refolded self-mailers will require tabbing (also called wafer sealing) before entering the mail stream. Depending on your layout, pieces will require one or two wafer seals on the open edge of the piece, and must be positioned to not obscure the address or indicia area. The proper orientation of these tabs, as well as the address portion of your mailer, is determined by your postal class, design and final size of your piece. Let Bindery1 help you with this important planning step.

Stagger Stitches for Refolding – Saddle-stitched booklets should be designed so the stitches are staggered after refolding. This minimizes stress on the spine, which can manifest itself as wrinkling and tearing. Also, refolding may cause pushout away from the final fold, which causes the open edges of a refolded piece to appear uneven. Again, advance planning with Bindery1 can help avoid these problems.

The Bindery1 Advantage
Let Bindery1 help you minimize the impact of the new postal rates for your direct marketing campaigns. Our production versatility, including refolding inline with saddle stitching, inkjetting and wafer sealing, is ideal for project quantities from the thousands into the tens of millions. And our experienced planning experts will help you prepare your projects for the most efficient production processes and mailing rates available. Call us today to discuss your next application.