Relay® Mailing Folders Inserters
Inserting mail into envelopes can be a time-consuming and costly task for your business. Reliable, fast and accurate our Relay folder inserters will ensure your critical mail is assembled and out the door on time, every time, without the inherent errors that come with manual handling.
The most convenient way to automate your mail processing.
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In an age of multi-channel communications, you need the best way to break through the clutter and gain more engagement from your customers.
Meet the Product Range
Relay® 1000
Relay® 4500
Relay® 6000
Relay® 8000
Relay® 9000
Optional extras
Relay® Integrity
Relay® Communication Hub
Relay® Print Manager
Compare the Relay folder inserter range
The Relay series scales from a compact desktop inserter to a high-volume production system. All fold, insert and seal mail automatically; they differ in speed, monthly capacity, number of feeders and the optional integrity software for page-level verification. Match the model to your monthly mail volume.
| Relay 1000 Compact desktop | Relay 4500 Office volume | Relay 6000 Mid-volume | Relay 8000 Higher volume | Relay 9000 Production | |
|---|---|---|---|---|---|
| Throughput (up to / hour) | 900 | 3,500 | 4,300 | 5,400 | 4,000 |
| Monthly capacity | 4,000 | 20,000 | 120,000 | 120,000 | 500,000 |
| Feeders | 1 sheet, 1 insert | 2 sheet, 1 insert | 4 sheet + 3 insert | 4 sheet + 4 insert | 6 feeders |
| Max envelope (D x W) | 121 x 235 mm | 164 x 242 mm | 162 x 241 mm | 267 x 330 mm | 267 x 330 mm |
| Fold types | C, Double | C, Z, Half, Double | C, Z, Half, Double, No Fold | C, Z, Half, Double, No Fold | C, Z, Half, Double, No Fold |
| Page-level verification (optional software) | — | All folds | All folds | All folds | All folds |
| Programmable jobs | — | — | 24 | 24 | 24 |
| Best for | Low-volume offices | Regular office mailings | Mid-volume mailrooms | High-volume mailrooms | Production mail operations |
Throughput and capacity figures are maximums and vary with mail piece, fold type and configuration. Full specifications are available in each model's brochure.
Resources
Relay folder inserter: frequently asked questions
What is a folder inserter?
A folder inserter is a machine that automatically folds documents, inserts them into envelopes along with any additional items, and seals the envelope — turning loose sheets into finished, ready-to-mail items without manual handling. The Relay range covers everything from a compact desktop unit to a production system handling up to 500,000 pieces per month.
How many envelopes can the Relay folder inserters process?
It depends on the model. The compact Relay 1000 folds, inserts and seals up to 900 envelopes per hour; the Relay 4500 up to 3,500; the Relay 6000 up to 4,300; and the Relay 8000 up to 5,400 per hour. The Relay 9000 is built for production, with throughput up to 4,000 per hour and a monthly capacity of up to 500,000 pieces.
How do I choose the right Relay model?
Match the model to your monthly mail volume and complexity. Low-volume offices suit the Relay 1000 or 4500; mid-volume mailrooms the Relay 6000; higher volumes the Relay 8000; and production operations the Relay 9000. Also consider how many document and insert feeders you need, and whether you require page-level verification — available as optional software on the 4500 and above.
How does a folder inserter make sure the right pages go in the right envelope?
On the Relay 4500 and above, optional integrity software reads marks or barcodes on each page — using Optical Mark Recognition, 1D or 2D barcodes — to verify that all the correct pages for a recipient are gathered before the envelope is sealed. This protects against mismatched documents, which matters for confidential or regulated mail in sectors like finance, legal and healthcare.
Can the Relay inserters handle different fold types and envelope sizes?
Yes. The range handles multiple fold types — C, Z, half and double folds, with a no-fold option on the 6000 and above — and a range of envelope sizes, up to 267 x 330 mm on the Relay 8000 and 9000. The Relay 9000 feeds paper from 60 to 200 gsm in portrait or landscape automatically, with no manual size or thickness adjustment.
What's the difference between a folder and a folder inserter?
A paper folder only folds documents ready to be enveloped separately, whereas a folder inserter folds the documents and automatically inserts them into envelopes and seals them in one process. The Relay range are folder inserters, handling the full fold-insert-seal workflow. If you only need documents folded, the OfficeRight DF800 and DF900 paper folders are the simpler option.
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