Formax FD 6204 Folder/envelope inserter -
  • Up to 15,000 per month
  • 325 sheet hoppers/250 envelope
  • Paper Size 3.5" x 5" to 9" x 14"
  • OMR option
  • Max from a sheet feeder: 3. total pcs 5
Photos of the folds of the Formax FD 6204 Folder/envelope inserter

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Item #: Formax-6204
Availability: Please call for help with selection
Price: $9,195.00

    The Formax FD6204 Folder/Inserter has a new color screen and updated exterior styling. It is rated to process up to 15,000 mail envelopes per month at speeds up to 2200 pieces per hour.

    There are 4 models in the 6204 Series folder / envelope machines. All models automatically fold and insert paper into an envelope, and optionally seal the envelope. You can take up to 3 sheets from the first feeder and insert a maximum of 5 pieces into an envelope. The sheet feeders handle paper from 3.5" x 5.125" to 9" x 14" paper. The insert feeder handles reply cards or envelopes or a piece that can be inserted without folding. Sheet feeders hold 325 and the envelope feeder 250.

    All models share a clamshell design with internal rollers which results in a much quieter machine than some others on the market. Fold types are C, V, Z and double parallel (fold in 1/2 and then in 1/2 again). The models differ in the number of feeders.


    6204-Basic 1 - $9195.

    One sheet feeder. Fold and Insert 1-3 sheets.

    6204-Advanced 1 - $10,350.

    One sheet feeder & one insert feeder. Fold & insert 1-3 sheets plus one reply card or envelope.

    6204-Basic 2 - $12,450.

    Two sheet feeders. Take 1-3 sheets from feeder one, 1-2 sheets from feeder 2. Fold and insert.

    6204-Advanced 2 - $14,195

    Two sheet feeders & one insert feeder . Take 1-3 sheets from feeder one, 1-2 sheets from feeder two, or 1 reply card or envelope from insert feeder. Max 5 pcs per envelope.

    Optical Mark Recognition (number of pages vary)

    The 6204 Advanced 2 model is available with an Optical Mark Recognition (OMR) reader. This option allows you to send invoices, reports or statements of varying numbers of pages to different recipients. You print them out in order, place the stack in the 6204, and the envelopes are properly filled. It requires your programmers to put small registration marks on the pages (we can provide a guide) or you can purchase our MailDoc software to do it for you. Call us for more information.

    You can see a brochure on MailDoc here:

    If you would like to get a quote on a folder inserter that will work for you, please fill out our

    We will send back a quote including freight, setup, training and on-site warranty.

    The Right Envelope

    These machines normally use a #10 standard commercial envelope with rounded-corner flaps that form a V shape. Envelopes with other kinds of flaps will not work. If you need to change the envelope, we can recommend a low-cost supplier.

    Order process, Warranty, Setup and Delivery

    When you place an order for a FD6204, we want to make sure that your jobs and the stock you use can be handled by the machine. We discuss your process in detail, make any necessary recommendations, and have you send samples of your jobs to the manufacturer. They are tested upon receipt. When approved, Formax will send you a written guarantee that the tested materials work in the machine.

    Upon payment, the FD6204 folder / inserter is sent from the factory. It normally arrives within 10-15 business days. It comes with a 90 day on-site warranty, which includes setup and training by a technician from your local area. If you have a problem during the warranty period, your local technician must be on-site within 24 hours of your call. All parts and labor are covered.

    On-Site Maintenance Agreement

    You can also purchase an annual on-site maintenance agreement that works the same way. All non-consumable parts and labor are covered, and 2 general maintenance visits per year are included. The annual cost of the agreement starts at $920 for the Basic 1.


    If you have been in business for at least 2 years, you have the option of leasing the machine for a period of 2 to 5 years. Approval can usually be done very quickly, normally over the phone. Please call for a quote.

    Feed Hoppers:Up to 325 sheets or approx. 45 BRE's
    Speed:Up to 2,200 pieces per hour
    Duty Cycle:
    Up to 15,000 pieces per month
    Paper Size:
    Sheet feeder: 3.5"- 14"L x 5" - 9"W
    Insert/BRE Feeder: 3.5" - 6"L x 5.1 - 9"W
    Envelope Size:6.3" - 9.8"W x 3.5" - 6.4"H
    Dimensions:47.2"L x 20.5"H x 16.5"D
    Weight:Approx. 165 lbs.
    Voltage:100 - 120 volts AC 50/60Hz
    Safety Certifications: •••
    UL Approved