Types of Mailing Equipment


Inserters: Previous Models / Folders & Inserters

Formax 6404 Series Folder Inserters

MSRP $25,595 - $37,395+ Call For Quote

Fully Automatic, High Capacity Formax 6404 Series Folder Inserters

Don’t settle for less! With outstanding standard features and a variety of options to choose from, the high capacity Formax 6404 series folder inserters will improve your productivity. Choose from models with two to six stations for a folder insert that meets your organization’s unique needs.

Reliable Formax Technology and Construction

The Formax 6404 Series Folder Inserters are powerful because they are running on Formax’s reliable technology and quality construction. The 6404 series can process up to 4,000 envelopes per hour and produce up to 60,000 finished pieces each month. The system can fold up to 10 sheets in a half-fold, and if you need tri-folded sheets it can do them in batches of 8 at a time. Each standard feeder case can hold 325 sheets, and there’s a cascade mode to maximize output by linking multiple feeders – for a total capacity of 1950 sheets!

The 6404 series can insert envelopes up to 6.3” H and 9.7” W – and can insert top, middle and bottom address documents into top flap envelopes. The 6404 series folder inserters can also fold and/or insert sheets, business reply envelopes and cards as an automatic part of the process – including stapled sets!

Within the folder inserter, double document detectors work hard to be sure that there aren’t any doubled sheets. This reduces the likelihood of jams and folding/insertion problems. In short, you can rely on the 6404 series to get the job done correctly the first time.

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The Formax 6404 Series Folder Inserters

With a full-color touchscreen control panel and a flip-down display, the 6404 folder inserter series is simple to use. Operators can easily program up to 25 jobs for easy recall and more efficient production. In addition, energy saving features will turn off the folder inserter after an hour of idle time so your organization can save on electricity costs.

The Formax AutoSeal® FD 1500Plus is built out of heavy steel, so it will be reliable and dependable for years to come. It packs a lot of power into its small footprint, and can process at a speed of up to 5,200 forms per hour. With an integrated output conveyer, your team can easily keep processed forms in sequential order.

The 6404 series features:

  • 2 – 6 fully-automatic feed stations
  • Full-color 5.7” touchscreen control panel, flips down and reverses for use on opposite side
  • 25 programmable jobs
  • Large power stacker holds up to 500 filled envelopes, with reverse stacking output
  • Water Level Detection alert on control panel
  • AutoSetTM: One-touch set-up
  • Large, top-loading envelope hopper holds up to 325 envelopes for continuous operation
  • Double-document detector for exceptional security
  • Diverter: Sensors redirect double documents and incomplete sets without interruption
  • Processes up to 4,000 envelopes per hour
  • Fold types: C, Half, Z, Double Parallel and no fold
  • Folds up to 10 sheets of paper (Half-fold) and up to 8 sheets (Tri-fold)
  • Energy-saving automatic standby mode after 1 hour

Additional options include a high-capacity document feeder that feeds up to 725 sheets, production feeders for up to 1200 sheets of 325 BREs, side exit tray for up to 500 filled envelopes, Barcode Recognition (BCR), Optical Mark Recognition (OMR), short feed trays, custom cabinets and 402 series joggers.


Feed Hopper Capacity:Up to 325 sheets, 20# paper (each feeder)
Envelope Hopper Capacity:Up to 325 envelopes, top-loading
Power Stacker:Up to 500 filled envelopes, reverse stacking output
Side Exit Tray (optional):Up to 500 filled envelopes
Speed:Up to 4,000 pieces per hour, #10 envelopes
Duty Cycle:Up to 60,000 pieces per month
Paper Size*:3.5” – 14” L x 5.1” – 9” W
Envelope Size*:6.3” – 9.7” W x 3.5” – 6.3” H
Dimensions:72” L x 36.5” H x 16.5” D (four-station models)
Weight:Approx. 242 lbs (four-station)
Voltage:100 Volts AC 50/60Hz
Safety Certifications:UL, CE approved

* Paper & envelope specifications may vary. All media must be tested.
** Bottom-address documents can be processed only in Half and Z-fold modes, up to 5 sheets.

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MSRP $25,595 - $37,395+ Call For Quote