Types of Mailing Equipment


Inserters: Current Models / Folders & Inserters

Formax 6406 Series Inserter

Standard features of the Formax 6406 Series Inserters includes a large vertical output stacker which can hold up to 500 filled envelope and a top-loading envelope hopper with a capacity of up to 325 envelopes which can be refilled on-the-fly. Double document detectors located at each feeder and the insertion area ensure no double documents are fed into the system. The 6406 Series utilizes electromechanical detectors which can operate with any print density, paper color, thickness or paper dust. Documents requiring inspection can be delivered automatically to the divert station. The 6406 Series also offers energy savings with its auto standby mode, which goes into effect after 1 hour of idle time.

One of the many user-friendly features of the Formax 6406 Inserter is the 7” full-color touchscreen control panel with graphics-based display and automatic paper and envelope presence sensors. AutoSetTM allows operators to load envelopes and documents, then adjusts all settings automatically with the ability to store up to 50 programmed jobs for instant recall. Its powerful folding capacity folds up to 10 sheets (half fold) or up to 8 sheets (tri-fold) at one time, plus it’s capable of folding and inserting top, middle and bottom-address documents into top-flap envelopes.** Cascade Mode allows users to link feeders for continuous operation: when one feeder empties, another takes over.

The versatile 6406 Series can be configured to accommodate a range of folding and inserting applications. Models are available with 2 to 6 stations for flexibility and include a variety of input configurations: a high-capacity document feeder for up to 725 sheets, 1 or 2 high-capacity production feeders, standard and special feeders, and short feed trays.

An optional CIS Scanner reads OMR, 1D and 2D Barcodes and OCR printed anywhere on the page, which provides the ability to
automatically insert multiple-page documents, eliminating the tedious task of manually collating and inserting. Additional options include
high-capacity production feeders, short feed trays for small inserts or BREs, side exit trays, custom cabinets and 402 Series Joggers.

Operating Features

Full-Glass Color Touchscreen: 7” touchscreen display features graphic icons for simple, intuitive use
Modular Flexibility: Configurations are available with 2-6 fully-automatic feed stations
AutoSetTM: Load envelopes and documents and the 6406 Series will adjust all settings automatically
Paper & Envelope Presence Sensors: Control panel displays which feeders need to be refilled
Mid-Volume Processing Speed: Processes up to 4,000 envelopes per hour
50 Programmable Jobs: Program frequently used jobs for quick and easy operation
High-Capacity Vertical Output Stacker: Holds up to 500 finished envelopes with reverse stacking output, maintaining printing order
Large, Top-Loading Envelope Hopper: Holds up to 325 envelopes with on-the-fly reloading for continuous operation
Handles a Variety of Envelope Sizes: Inserts into envelopes up to 6.3” H x 9.7” W
Variety of Fold Types: C, Half, Z, Double Parallel and no fold
Daily Mail Mode: Easily inserts stapled sets
Multi-Feeding: Allows for a set number of pieces to be pulled from one feeder, then collated and
inserted automatically
Cascade Mode: Feeders can be linked for continuous operation, when one feeder empties, another
takes over, allowing operators to refill as needed until the job is complete
Powerful Folding Capability: Folds up to 10 sheets (half fold) or up to 8 sheets (tri-fold) at once
Versatile: Folds and/or inserts sheets, BREs and cards automatically
Insert Capability: Folds/inserts top, middle and bottom address documents into top-flap envelopes
Eco Mode: Saves energy by automatically switching into standby mode after one hour of inactivity

Document Security Features

Double Document Detection: Electromechanical detectors located at each feeder and the insertion area operate with any print density, paper color or thickness, to provide exceptional security
Divert Station: Sensors redirect double documents and incomplete sets without interruption


CIS Scanner: Reads OMR 1-track, OCR, 1D Barcodes and 2D Data Matrix codes, printed horizontally or vertically anywhere on the page
Production Feeders: 1 or 2, each feeds up to 1,200 sheets or 325 BREs
Side Exit Tray: Holds up to 500 filled envelopes OMR, BCR and OCR: Optical Mark, Barcode and Optical Character Recognition for added security
Short Feed Trays: Designed for small inserts and BREs
Custom Cabinets: Enclosed cabinets on casters with a key lock for secure storage
402 Series Joggers: Square and remove static electricity from documents prior to processing


Feeder Capacity: Up to 325 sheets, 20# paper (each feeder) / 725 (Production Feeder)
Envelope Hopper Capacity: Up to 325 envelopes, top-loading
Vertical Output 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
Programmable Jobs: Up to 50
Paper Size*: 3.5” – 14” L x 5.1” – 9” W
Envelope Size*: 6.3” – 9.7” L x 3.5” – 6.3” W
Dimensions: 65” L x 32” 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

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