Formax FD 6604 Series Folder Inserter
The Formax FD 6604 Series is a fully automatic folder inserter configurable with 2 to 7 insert stations, processing up to 4,300 envelopes per hour. All For Mailers still supports it with parts, supplies, and service.
Description
About the Formax FD 6604
The Formax FD 6604 Series adapts to any of your inserting and folding jobs and can be configured with 2 to 7 insert stations for unparalleled flexibility. It folds and inserts documents addressed on the top, middle or bottom into top-flap envelopes, and its full-color 10.4-inch touchscreen tilts to the operator’s height for easy, intuitive setup.
The FD 6604 processes up to 4,300 envelopes per hour and up to 80,000 finished pieces per month, folding up to 10 sheets in half-fold and up to 8 in tri-fold. Standard feeders hold up to 325 sheets, a high-capacity document feeder holds up to 725, and cascade mode links feeders for a total capacity of 2,025 sheets. AutoSet automates fold and envelope settings, up to 25 jobs can be stored, and options include a thin booklet feeder, one or two production feeders, high-capacity envelope hopper and output conveyor for up to 1,000 each, plus 1D/2D BCR and 1-track/2-track OMR with CIS scanning.
Formax FD 6604 Series Specifications
| Model | Formax FD 6604 Series |
|---|---|
| Speed | Up to 4,300 pieces/hr |
| Feed stations | Configurable from 2 to 7 insert stations |
| 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 |
| Cascade mode capacity | 2,025 sheets total |
| Envelope type | Top-flap envelopes; documents addressed top, middle or bottom |
| Control panel | 10.4” full-color touchscreen, tilts to operator height |
| Setup | AutoSet automates fold and envelope settings |
| Job memory | Up to 25 jobs |
| Options | Thin booklet feeder, one or two production feeders, high-capacity envelope hopper and output conveyor (up to 1,000 each), 1D/2D BCR, 1-track/2-track OMR with CIS scanning |
| Availability | Previous model — still supported; current successor is the Formax 6608 Series |
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? Our current Formax 6608 Series carries this modular, high-capacity design forward with faster setup and modern feeder options — ask us for a quote.
Straight talk: some parts for the Formax FD 6604 Series are getting hard to find — but it was built to last. These were genuinely well-made units, and a well-cared-for one may run for years yet. It’s off the current price lists, and while we can still source many parts, certain components — most often boards, displays and electronics — are increasingly scarce. We can often keep one running. We just can’t promise it indefinitely.
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.
Already own one? Call 866-430-2874 before you commit to a major repair — we’ll tell you honestly whether the part exists and whether the repair is worth it. SuppliesForMailers.com still stocks consumables.
Shopping today? We’d steer you toward a current, supported platform — the Formax FD 6104, FD 6210, FD 6306, FD 6308, FD 6406 and FD 6608. Tell us your volume and piece sizes and we’ll match you to the right machine, with parts, service and lifetime phone support behind it.
Need supplies or parts? Visit SuppliesForMailers.com.
Additional information
| Speed (pieces/hr) | Up to 4,300 pieces/hr |
|---|---|
| Number of Feed Stations | Configurable from 2 to 7 insert stations |
| Sheet Capacity | Up to 10 sheets half-fold, up to 8 sheets tri-fold |
| Feeder Capacity | Up to 325 sheets per standard feeder |
Official product video from Formax USA.
Frequently Asked Questions
Is the Formax FD 6604 still available new?
No. The FD 6604 Series is a previous model. All For Mailers still supports installed FD 6604 units with parts and service and recommends the current Formax 6608 Series for new purchases.
Can I still get parts and supplies?
Yes — visit SuppliesForMailers.com or call 866-430-2874.
How does the FD 6604 compare with the current FD 6608?
Both are rated up to 4,300 envelopes per hour, with 325-sheet standard feeders and 2-to-7 station modularity. The current 6608 Series carries that forward with a 10-inch color touchscreen, up to 50 programmable jobs and an optional CIS scanner, against the 6604’s 25 stored jobs.






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