Federal Envelope Company

What Federal Envelope Company does

Federal Envelope Company is a privately held, family-owned custom envelope manufacturer founded in 1965, originally in Chicago's historic Printer's Row and now headquartered at 608 Country Club Drive, Bensenville, Illinois, with an additional manufacturing site in Elk Grove, Illinois. The company produces Diagonal Seam, Open Side, and Open End envelopes in configurable sizes ranging from 1.75 x 1.75 inches up to 30 x 36 inches, and prints them using Lithographic, Flexographic, and Jet presses with up to six colors and full customization against customer artwork. Stated production capacity is 200 million envelopes per month across all styles, and materials are sourced exclusively from SFI-certified forests, supporting a sustainability positioning for B2B buyers.

The company sells directly to business and commercial customers through phone-based sales and a PDF quote-request workflow, without distributors, intermediaries, or e-commerce. Pricing is quote-based, varying by envelope style, size, color count, printing method, and order quantity, and is not publicly disclosed. Marketing and demand generation rely on the company website, product and print-spec pages, and direct phone outreach rather than digital advertising campaigns. The customer base consists of B2B buyers in the Chicago metropolitan area and surrounding regions needing custom envelopes for correspondence, direct mail, and promotional materials; no named customer logos are disclosed and no management team, headcount trend, or revenue figures are publicly available.

Name

Federal Envelope Company

Legal name

Federal Envelope Company

Website

https://federalenvelope.com

Company type

Private

Founded year

1965

Operating status

Operating

Headcount range

11–50 employees

Short description

Federal Envelope Company is a family-owned custom envelope manufacturer founded in 1965 in Illinois, producing Diagonal Seam, Open Side, and Open End envelopes with multi-color Litho, Flexo, and Jet printing at a capacity of 200 million units per month for B2B customers in the Chicago metropolitan area.

Ownership category

akta.pro rank

Product category

Custom Envelope Manufacturing

SIC

Commercial Printing (2750)

akta.pro primary industry

Envelopes & Mailing Products (mailers, padded envelopes) (IMAMAHAD)

Keywords

• Custom envelope manufacturing
• Commercial printing services
• Envelope converting
• Lithographic printing
• Flexographic printing

Headquarters

HQ city

Bensenville

HQ country

United States

HQ region

North America

Offices2 records

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Supply Chain, Operations, Personnel, Infrastructure

Revenue model

1. Envelope Manufacturing and Sales: Custom envelope manufacturing and printing services sold directly to business customers. Products include Diagonal Seam, Open Side, and Open End envelopes in various sizes. Revenue generated through one-time transaction sales based on customer specifications and order quantities.

Pricing tiers

Go-to-market motion1 record

Distribution channels1 record

Marketing channels3 records

Core offering

Federal Envelope Company manufactures custom envelopes in three styles (Diagonal Seam, Open Side, and Open End) across a wide range of sizes, with in-house printing capabilities including Lithographic, Flexographic, and Jet printing methods supporting up to six colors. The company produces over 200 million envelopes per month for business customers needing custom-manufactured, branded envelopes for correspondence, direct mail, and promotional use.

Product overview

Federal Envelope Company offers a portfolio of custom envelope products and printing services. The core product line includes three envelope types: Diagonal Seam (up to 9.5 x 12.5 inches), Open Side (up to 23 x 31 inches), and Open End (up to 30 x 36 inches) envelopes. These envelope products are complemented by three printing service options—Lithographic Printing, Flexographic Printing, and Jet Printing—all supporting up to six colors and full customization capabilities.

Differentiator

Problem solved

Functional benefit

Products and services

• Diagonal Seam Envelopes Diagonal seam style envelopes with configurable dimensions ranging from 1.75 x 1.75 inches minimum to 9.5 x 12.5 inches maximum, manufactured to customer specifications for business customers.
• Open Side Envelopes Open side style envelopes with configurable dimensions ranging from 1.75 x 1.75 inches minimum to 23 x 31 inches maximum, manufactured to customer specifications.
• Open End Envelopes Open end style envelopes with configurable dimensions ranging from 1.75 x 1.75 inches minimum to 30 x 36 inches maximum, manufactured to customer specifications.
• Lithographic Printing Services Lithographic printing service with variable color availability depending on the press used, featuring 133-150 lpi screen resolution, used to print custom designs on envelopes.
• Flexographic Printing Services Flexographic printing service supporting up to 4 outside colors plus 1 inside color (4/1 configuration) with 120 lpi screen resolution for envelope customization.
• Jet Printing Services Jet printing service for envelope customization, offered alongside Flexo and Litho printing capabilities for full multi-color customization.

Quantifiable outcome

• 200 million envelopes manufactured monthly across all styles

Segments1 record

Ideal customer profiles1 record

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature5 records

Partnerships

One partnership is on record.

• Sustainable Forestry Initiative (SFI)minorOthersFederal Envelope Company is SFI-certified and sources materials only from SFI-certified forests. This certification indicates the company's commitment to sustainable forestry practices. SFI program participants plant 650 million trees annually and manage over 150 million acres in North America.

Scale indicators3 records

Recent moves4 records

Expansion highlights3 records

Direct peers

• Tension Corporation: US custom envelope manufacturer offering a multi-style product line and printing services to B2B customers, including direct mail and business correspondence — directly comparable to Federal Envelope in product category, customer type, and customization model.
• Quality Envelope (a Cenveo brand): Established envelope printing brand under Cenveo focused on custom printed envelopes for business and direct mail use, serving as a direct comparable in product, customer base, and custom-print capability.
• Premier Envelope & Print: Custom envelope manufacturer and printer serving business correspondence and direct mail markets — comparable to Federal Envelope in product scope, customization, and B2B commercial customer base.
• The Envelope Place: US custom envelope printer offering multiple envelope styles and custom printing for business customers, closely comparable to Federal Envelope in product breadth, customization, and B2B direct-sales model.

Broad incumbents

• Cenveo Inc. Large diversified printing and envelope manufacturer whose portfolio includes custom envelopes alongside broader commercial print and packaging, providing a scaled incumbent benchmark for Federal Envelope's niche operations.
• Quad/Graphics: Large commercial printing platform serving enterprise marketing and direct mail customers. Adjacent rather than direct overlap, but competes for the same marketing-services wallet and serves as a benchmark for scale economics in commercial print.
• Smurfit Westrock: Global paper-based packaging giant with paper, containerboard, and converted paper products including envelopes-adjacent mailing products. Comparable as a large incumbent in the broader paper-converting value chain relevant to Federal Envelope's sourcing and end markets.

Market position

Strengths4 records

Weaknesses4 records

Competitive moat3 records

Key risks5 records

Key highlights6 records

Customer concentration

• LinkedInlinkedin.com/company/federal-envelope-company

Compliance1 record

Revenue estimate

Valuation estimate

Number of profiles

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about Federal Envelope Company