Direct Mail and Letter Fold Production System

The Direct Mail and Letter Fold Production System from MBO America is an efficient, high speed roll-to-folded product finishing line, designed to have a simple set up and high production rate. The system will cut the web to the proper sheet length using a chop-cut, or chip-out cut, as needed. The sheet can be cut from 5” long to 48” long, folded and delivered as is needed. Print to cut register control is achieved by a print register mark on the web and the sheeter will register in real time for all cuts. After sheeting, the sheet will be registered and folded to the required output pattern using up to 6 buckle plates allowing for many direct mail fold patterns. The folded product will then be slit as needed and delivered as a 1 up, 2-up, 3-up, or 4-up final folded product. The system can use single blade slitters between the products or gutter trim slitters between the products depending upon the type of work. Tooling is flexible and easy to change. The near-line system has a maximum web sheeting speed of 824 fpm.  The system is generally used for direct mail, letters, newsletters, general commercial, brochures, half folds, 3 panel folds and 4 panel folds.  Click here for more info

General Specifications “At-A-Glance”

  • Roll Diameter Maximum:       1320mm (52”)
  • Web Width Minimum:            150mm  (6”)
  • Web Width Maximum:            520mm (20.5), 572mm (22.5″), 762mm (30″)
  • Web Speed Maximum:            250m/m (824fpm)
  • Paper Stock Minimum:           40 gsm
  • Paper Stock Maximum:          250 gsm
  • Smallest Fold Length:            60mm  (2.4”)
  • Max Folded Width:                 Up to web width
  • Max Number of Folds:           6 Buckles in main parallel unit
  • Max Stacks Across:               3 Up or 4 up dependent upon web width


  • MBO UW 52 Unwinder
  • MBO PFS Web-Based Plowfold System
  • MBO SPM Split and Merge Unit
  • MBO SVC High Speed Sheeter
  • MBO DFT DIGI-Folder FW I
  • MBO ASP  high capacity delivery with marking device
  • Optional Palamides delta automatic delivery
  • Optional MBO DPS 60 Dynamic Perf & Score Unit (up to 22.5″ web width only)

Technical Specifications

MBO High Speed Letterfold II 5mm Chipout (810 ft/min!)

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