Two way mailed document with two sided variable color information

Abstract

A mailing envelope with a plurality of inserts is made by imaging variable color indicia on both faces of a paper substrate and imaging sense marks, and reply indicia, on at least one face of the substrate. The sense marks are used to properly align and slit the substrate web into a web of pre-determined width (removing the sense marks), and then label portions are flexographically printed on the first face of the web with magnetic ink. Adhesive and a release liner (e.g. using transfer tape) are applied to the second face of the web at the label portions and the labels are die cut from the label portions. The web is cut into sheets of predetermined length, each sheet including at least one set of labels, and the sheet is buckle folded to form a folded sheet with a plurality of panels in the sheet, at least one panel having a set of labels. The folded sheet is then trimmed to form at least two distinct inserts from the folded sheet, at least one distinct insert comprising a reply insert with reply indicia on it. The inserts are inserted, with a reply envelope, into an outgoing envelope to produce a mailing envelope. Typically the folded sheet has at least four panels, including at least two aligned fold lines, and trimming is accomplished by severing the sheet at the aligned fold lines to form at least three different inserts, at an inserter.