26,000 A5 six-page personalised letters with membership cards and A4 two-page personalised colour letters were split and sent in personalised C5 non window envelopes across weekly batches.
We have fulfilled this project for a number of years for a well-known national society. Previously, the membership cards were credit card style plastic cards. We purchased the colour printed cards and then overprinted the personalisation using a thermal card printer. The cards were affixed and matched to a personalised letter using a glue dot and enclosed into a C5 window envelope. This project also included handling regularly supplied data files, an extensive proofing process, and reporting.
26,000 A5 six-page personalised letters with membership cards and A4 two-page personalised colour letters were split and sent in personalised C5 non window envelopes across weekly batches. The client was looking to reduce the unit cost of each pack whilst changing to their new branding. We had to ensure the quality of the card and that it could be easily removed but wouldn’t drop out during production. The process required intelligent fulfilment of three-way matching of the letter, mailer, and envelope.
The biggest savings could be achieved by moving away from plastic membership cards and instead using a pop out card which could sit in an A5 six-page mailer. The client supplied new artwork using their new branding, which is now consistent across all three elements of the pack. We created samples of the mailer using several different paper stocks to ensure the quality was satisfactory and the colour print matched the new brand guidelines.
Once the stock was agreed, we tested the pop out membership card by die-cutting a rectangular perforation to the middle page of the mailer. There was a little bit of trial and error to ensure it was the right depth so that the card could be easily separated from the mailer by the recipient while remaining secure. WDM fulfil matched mailings every day, but this one was more complex. The letter had a dark background which meant that it couldn’t be recognised by the sensors on the high-speed page feeder. Therefore, the letter had to be folded offline and enclosed from a rotary feeder. Our Buhrs enclosing line required reconfiguring and reprogramming to handle the three-way match from two insert stations and the envelope feeder.
We achieved a substantial saving for the client against last year’s project while improving the overall look and feel of the pack. The integrity of the mail piece is now 100% guaranteed through the use of 2D barcodes and camera matching, and the production process is more efficient than before.
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