GUSSET Envelopes (Envelopes)
Gusset Envelope Printing from £180 | Extra Capacity FREE DELIVERY**
Extra Capacity Envelopes are available in C4 size only — and offer a 25mm capacity over Standard envelopes — if you want to insert thicker material or a greater quantity of documents.
They are suitable for posting many different types of items including books and catalogues, photos, branded artwork, presentations. Especially useful for eBay and Amazon sellers.
TradePrintingUK print these in full colour with your company brand or logo.
Extra Capacity GUSSET Envelope Features:
- C4 envelope size
- POCKET Short-Edge flap as standard on all sizes
- Premium White 120gsm paper stock
- Strong Peel & Seal flap as standard on all sizes
- BOXED: in 125's
- SHELF-LIFE: up to 5+ years
- Our Gusset Envelopes are PEFC Certified, manufactured with 120gsm paper / from responsible, sustainable sources.
Envelope Size — UK Standard Dimensions
| Envelope Size | Dimensions (mm) W/H | Equivalent Paper Size | Typically Used For | Glue-type / Flap |
|---|---|---|---|---|
| C4 | 324 x 229 | A4 | Unfolded A4 documents, thin Catalogues | 120gsm Peel & Seal 64mm |
**NOTE: Artwork supplied with "Heavy Ink Coverage" or "Full Bleed" is £POA
** GB, N.Ireland, Republic of Ireland — 1 x 30kg box ONLY. SCOTTISH HIGHLANDS, ISLANDS & EUROPE WILL INCUR A SMALL SURCHARGE.
A: Gusset Envelopes are specially designed envelopes with an expandable side or base (often called a 'gusset') that allows them to hold larger, bulkier, or thicker items.
They are ideal for sending documents, books, catalogues, brochures, promotional materials, or even small electronic devices that are too thick for standard envelopes.
A: They provide extra capacity (up to 25mm), ensuring that contents arrive without being folded or damaged.
Printing them with your company brand or logo enhances professionalism, reinforces your brand identity, and ensures your post stands out, making a positive impression on recipients like your customers, clients, or partners.
A: They are widely used by businesses sending annual reports, marketing departments for promotional material distribution, e-commerce sellers (especially eBay and Amazon) for posting items like photos, licences, or small products, and any UK organisation needing to send multiple documents without creasing.
A: Our Gusset Envelopes are manufactured from a high-quality 120gsm premium white paper, providing a strong and professional feel for your post.
A: We offer our Gusset Envelopes in a C4 size (324mm x 229mm) only, with the gusset depth expanding to around 25mm to accommodate your bulky items.
A: All our Gusset Envelopes feature a strong Peel & Seal 64mm flap as standard.
This offers superior security for the contents and has a long shelf life of up to 5 years, ensuring the adhesive remains effective even with long-term storage.
A: Our Gusset Envelopes can be printed in full colour on the front for your company brand or logo only.
Printing on the reverse is not available for this product.
A: 125 envelopes is the lowest quantity we print of these, as they come pre-made in boxes of 125.
A: The standard turnaround for Gusset Envelopes is 8-12 working days..
We offer FREE delivery for one 30kg parcel to GB, Northern Ireland, and the Republic of Ireland. Scottish Highlands, Islands, and Europe may incur a small surcharge.
A: Our Gusset Envelopes are supplied boxed in quantities of 125, making them easy to store and manage.
A: Yes, our Gusset Envelopes are PEFC Certified, indicating they are manufactured from responsible, sustainable sources. This makes them an eco-conscious choice for your mailing needs.
A: For the best results, please provide a press-ready PDF file in CMYK colour mode.
Ensure all images are high-resolution (350dpi), all fonts are embedded or converted to outlines, and that you have included 3mm of bleed on all edges.
A: Yes, artwork supplied with 'Heavy Ink Coverage' or 'Full Bleed' will incur an additional charge (POA - Price on Application).
It's best to confirm this BEFORE placing your order.
A: The page does not specify if the ink is waterproof. It is generally advisable to protect printed envelopes from moisture to prevent ink from running, especially if contents are sensitive to water.
A: TradePrintingUK.com is one of the best options for this specific region as we our factory is based in Northern Ireland.
Shipping: We offer FREE Delivery to the majority of the UK and Ireland, including the Republic of Ireland.
Logistics: We use reliable couriers like DPD, Royal Mail, Parcelforce and UPS, rather than budget services like EVRI.
Best For: General business stationery (NCR forms, flyers, pull-up roller banners, printed envelopes, mass offering for Catholic Church) where you want to avoid high surcharges for NI/ROI.
What are Gusset Envelopes?
Gusset Envelopes are used by individuals, businesses, and organisations in the UK and Ireland to send documents or over-sized items that are too bulky to fit into a standard envelope.
These C4 size Gusset envelopes have an expandable side or base that allows them to hold larger, bulkier or thicker printed items such as Annual Reports, Catalogues, Brochures plus promotional materials.
They are also useful for posting items such as books, clothing, or small electronic devices.
What does a Gusset Envelope look like?
Examples of content that can go into a Gusset Envelope?
Primarily used for posting and transportation purposes rather than storage
In terms of inside content, some examples may include multiple items together including:
- Cover letter or other accompanying documents
- Corporate Brochure or catalogue highlighting products or services
- Product sample or Promotional item
- An invoice or payment request
- Return label or instructions for returning the item if necessary
Printed Gusset Envelope Specification
Gusset Envelope flaps are Peel & Seal to ensure the contents aren't tampered with.
The gusset depth expands to around 25mm, allowing gusset envelopes to securely hold a larger number of documents than a conventional C4 envelope.
The glue is very strong, and because it has a protective strip it can be stored for a long time without the risk of drying out.
The flap is a very large Pocket-style (on the short edge).
FREE DELIVERY** EXPLAINED
Prices are based on ONE free* parcel (*first outer box is FREE only within UK and Ireland) weighing up to 30Kg going to ONE address, via DPD48, Royal Mail Tracked 48 or UPS. to **GB, N. Ireland, Republic of Ireland
All SMALL Orders weighing Under 2Kg will be sent via Royal Mail 48hr Tracked.
*SCOTTISH HIGHLANDS & ISLANDS to us are anyone with the following Scottish Postcodes:
- HS
- IV
- KA27 - KA28
- KW
- PA20 - PA49
- PA60 - PA78
- PH17 - PH26
- PH30 - PH44
- PH49 - PH50
- ZE
DPD Benefits:
- Delivery slots available in 1-hour windows
- Track your delivery in real time
- Provide instructions for the driver
- Request the parcel to be left in a secure location
- Reschedule the delivery date
- Have the parcel delivered to a neighbour
- Redirect delivery to a different address (this may cause delays)
- Arrange delivery to a collection point
1 WORKING DAY UPGRADE Availability for – England, Scotland*, Wales to include an additional surcharge Trade Printing UK currently offer FREE Delivery on print to the majority of the UK and Ireland (*excluding Isle of Man, Scottish Highlands, Channel Islands — surcharge applies), but if you're in a hurry, we can expedite shipping after production finishes with other upgrade options.
Northern Ireland & Republic of Ireland are usually 1 working day by default due to logistics from our main factory.
Scottish Highlands and Isle of Wight — can take around 3 working days to deliver.
Isle of Man, Jersey and Guernsey — post Brexit - can take up to 1 Week to export. NO UPGRADES AVAILABLE!
Western Europe — post Brexit — can take around from 2 - 4 weeks to export and clear through Customs in your own country. Will be Charged at going rate.
DUBAI can take 7-10 days to export to.
Split addresses available at EXTRA cost. £POA
Actual shipping time of your print order will vary depending on where you are in the country and when you order. Working Day times are all Monday to Friday only as standard.
Shipping times EXCLUDE Weekends and Public Holidays (although sometimes our carriers choose to elect a weekend day to deliver to non-commercial premises). See our Terms & Conditions for more details on our logistics policy.
If you'll have MORE than one parcel in your print order that needs to be expedited, we will advise you at time of order and charge you accordingly.
NOTE: Once parcels are collected by our carrier, responsibility for on-time delivery rests with the carrier as circumstances may occur beyond our control (i.e. office closed, weather, strikes, flight delays, access denied etc).