Formax FD 6404 Series Folder Inserter
The Formax FD 6404 Series is a fully automatic, high-capacity folder inserter offered in two- to six-station models, processing up to 4,000 envelopes per hour. All For Mailers still supports it with parts, supplies, and service.
Description
About the Formax FD 6404
The Formax FD 6404 Series is a fully automatic, high-capacity folder inserter that pairs outstanding standard features with a range of options. Choose from models with two to six stations to build a folder inserter that meets your organization’s needs, all running on Formax’s reliable technology and quality construction.
The FD 6404 processes up to 4,000 envelopes per hour and up to 60,000 finished pieces per month, folding up to 10 sheets in half-fold and up to 8 in tri-fold. Each standard feeder holds up to 325 sheets, and cascade mode links feeders for a total capacity of 1,950 sheets. A full-color 5.7-inch touchscreen with a flip-down, reversible display keeps operation simple, AutoSet handles one-touch setup, and up to 25 jobs can be stored. Options include a 725-sheet high-capacity document feeder, production feeders, side exit tray, BCR, OMR, short feed trays and joggers.
Formax FD 6404 Series Specifications
| Model | Formax FD 6404 Series |
|---|---|
| Speed | Up to 4,000 pieces/hr |
| Feed stations | Configurable from 2 to 6 |
| Fold capacity | Up to 10 sheets half-fold, up to 8 sheets tri-fold |
| Feeder capacity | Up to 325 sheets per standard feeder |
| High-capacity document feeder | Up to 725 sheets (optional) |
| Cascade mode capacity | 1,950 sheets total |
| Control panel | 5.7” full-color touchscreen, flip-down reversible display |
| Setup | AutoSet one-touch setup |
| Job memory | Up to 25 jobs |
| Options | Production feeders, side exit tray, BCR, OMR, short feed trays, joggers |
| Availability | No longer in current production — parts and service still available |
| Feeders | Document feeder trays (325 sheets each); optional 725-sheet high-capacity document feeder; optional maxiFeeder (1,200 sheets / 320 BREs) |
| Paper size | Sheets 5.1-9.5 in W x 3.5-14 in L |
| Paper weight | 15-62.5 lb bond (60-250 gsm); up to 42.5 lb bond (170 gsm) when folded |
| Weight | 195 lbs (88.5 kg) 2 stations; 211 lbs (96 kg) 3/4 stations; 242 lbs (110 kg) 5/6 stations |
Downloads
Still Supported by All For Mailers
Even though this model is no longer in current production, All For Mailers still stands behind it. As a veteran-owned dealer whose people have been in the mailing and print-finishing industry since 1991, we help keep your equipment running with genuine parts, supplies, and experienced service support.
Looking to upgrade? All For Mailers can quote a current Formax office inserter that carries this design forward with a larger color touchscreen and modern feeding — just ask.
Protect what you have. These machines were built to last, and the mechanics will outlive the electronics every time. If you’re running one, put it on a quality surge protector, and add static protection — especially in dry winter air or on high-speed paper handling. Power spikes and static are what kill boards, and on these machines a board may not be replaceable at any price. It’s the cheapest insurance there is for equipment you can’t simply reorder.
Need supplies or parts? Visit SuppliesForMailers.com.
Additional information
| Speed (pieces/hr) | Up to 4,000 pieces/hr |
|---|---|
| Number of Feed Stations | Configurable from 2 to 6 |
| Sheet Capacity | Up to 10 sheets half-fold, up to 8 sheets tri-fold |
| Feeder Capacity | Up to 325 sheets per standard feeder |
| Feed Type | Document feeder trays (325 sheets each); optional 725-sheet high-capacity document feeder; optional maxiFeeder (1,200 sheets / 320 BREs) |
| Weight | 195 lbs (88.5 kg) 2 stations; 211 lbs (96 kg) 3/4 stations; 242 lbs (110 kg) 5/6 stations |
| Max Media Size | Sheets 5.1-9.5 in W x 3.5-14 in L |
| Media Thickness | 15-62.5 lb bond (60-250 gsm); up to 42.5 lb bond (170 gsm) when folded |
Official product video from Formax USA.
Frequently Asked Questions
Is the Formax FD 6404 still available new?
No. The FD 6404 Series is a previous model and is no longer built new. All For Mailers still supports installed FD 6404 machines with parts and service and can recommend a current successor.
Can I still get parts and supplies?
Yes — visit SuppliesForMailers.com or call 866-430-2874.
How does the FD 6404 compare with the current FD 6406?
Both are rated up to 4,000 envelopes per hour, with 325-sheet standard feeders and a 725-sheet high-capacity option, and both build from 2 to 6 stations. The current 6406 Series moves to a 7-inch full-color touchscreen with up to 50 programmable jobs, against the 6404’s 5.7-inch display and 25 stored jobs.
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