Types of Mailing Equipment


Inserters: Current Models / Folders & Inserters

Formax 6608 Series Inserter

The modular design of the Formax 6608 Series of Inserters allows it to adapt to almost any folding and inserting job. This series of inserters can be purchased with 2 to 7 stations offering maximum flexibility that can include a high-capacity document feeder for up to 725 sheets, 1 or 2 high-capacity production feeders, standard and special feeders, short feed trays and a thin booklet feeder.

A 10″ touchscreen control panel,  top-loading envelope hopper with a capacity of up to 500 envelopes,  vertical output stacker for up to 500 filled envelopes, and automatic paper and envelope presence sensors with indicators on the control panel are all standard on the Formax 6608 Series of inserters. Let’s not forget AutoSet, which allows an operator to load the envelopes and paper, press AutoSet, and the Inserter takes care of the rest! It measures all paper size in each tray and the envelope size then automatically sets the fold points. If it’s a common just, store it as one of 50 programmed jobs. Making setup even faster the next time you do it. The powerful folding capacity of the 6608 series allows for folding 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 and the inserter starts pulling from the next tray.

Double document detectors are located at both the feeder and insertion area to ensure the right documents get into the right envelopes and nothing extra. The intelligent 6608 Series utilizes electromechanical detectors which can operate with any print density, paper color, thickness or paper dust to make sure doubles are not being pulled. If it detects an error, documents requiring inspection can be delivered automatically to the divert station without interruption of the work flow. After an hour of sitting idle, the 6608 series will power down and go into standby mode to save energy.

Various levels of Barcode Recognition (BCR) and Optical Mark Recognition (OMR) are available and feature CIS scanning technology, which can scan codes printed in any location on a document. Optical Character Recognition (OCR) is also available, which uses page numbering in 1/1 or N-of-M format to ensure each set is complete before being inserted into an envelope.

Additional options include a thin booklet feeder for inserts up to 2.5mm thick, side exit tray, locking cabinet and 402 Series Joggers.

<b>Operating Features</b>

Full-Color Touchscreen: 10” touchscreen display features graphic icons for simple, intuitive use
Modular Flexibility: Configurations are available with up to 7 fully-automatic feed stations
AutoSetTM: Load envelopes and documents and the 6608 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 4,300 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 500 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 runs empty, another
takes over, allowing operators to refill as needed until the job is complete
Rugged 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

<strong>Operating Features</strong>

Five Models Available: Choose the configuration that best suits your applications
7” Color Touchscreen: Graphical interface provides quick, easy setup
50 Programmable Jobs: Handy for recurring or frequently processed applications
High-Capacity Vertical Stacker: Holds up to 500 finished envelopes in a neat, sequential order
AutoSetTM: Automatically senses and sets paper length, fold type, envelope size, fold length and double document detection. Simply load and go.
Envelope & Paper Presence Sensors: Graphic indicators on the touchscreen to assist operators
Enhanced Folding System: Fold/insert up to 5 pages in half-fold (up to 8 w/optional Productivity Pkg)
Multi-Sheet Feeding: Feed up to 3 sheets from one feeder (up to 10 w/optional Productivity Package)
Clamshell Design: Easy access to the paper path
Accumulate Before Folding: Documents are folded and inserted together
Double Document Detection: Electromechanical sensors are unaffected by dust, smudges or paper color, providing essential document integrity
Multiple Insert Capability: Fold and/or insert sheets, BREs and cards in almost any combination
Fold Types: C, V, Z, Double Parallel, no fold, Fold Only without Inserting
Daily Mail Mode: For inserting stapled sets
Seal and Non-Seal Capabilities
Cascade Mode: Maximizes output by connecting multiple feeders with the same document. When one feeder empties, the next automatically starts feeding, for a total hopper capacity of up to 650 sheets.
Eco Mode: Energy-saving feature places the inserter into sleep mode after 1 hour of inactivity

<strong>Document Security Features</strong>

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
Thin Booklet Feeder: Dedicated feeder inserts BREs or booklets up to 2.5mm thick
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 500 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 4,300 pieces per hour, #10 envelopes
Duty Cycle: Up to 80,000 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 With Thin Booklet Feeder:
60” L x 31” H x 18” D (four-station models)
79” L x 31” H x 18” 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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