• Up to 60,000 per month
  • 2 - 6 hoppers (325 ea); output stacker
  • Paper Size 3.5" x 5" to 9" x 14"
  • Bar code, glossy, & large feeder options
  • Up to 10 pcs per envelope (6" x 9.5")
Photos of the folds performed by the FD 6404 Folder/envelope inserter

Get a

Item #: Formax-6406
Availability: Many configurations. Call or send a QuickQuote
Price: $31,695.00

    The 6406 Series is versatile and available with 2 to 6 stations for flexibility, including a variety of input configurations: a high-capacity document feeder for up to 725 sheets, 1 or 2 high-capacity production feeders, standard and special feeders, and short feed trays.

    User-friendly features of the 6406 include the 7” color touchscreen control panel with graphics-based display and automatic paper and envelope presence sensors, a vertical output stacker which holds up to 500 filled envelopes, and a top-loading envelope hopper with a capacity of up to 325 envelopes which can be refilled on-the-fly. AutoSet allows operators to load envelopes and documents, then adjusts all settings automatically with the ability to store up to 50 programmed jobs for instant recall.

    The 6406 has a powerful folding capacity that folds up to 10 sheets (half fold) or up to 8 sheets (tri-fold) at one time. A Cascade Mode allows users to link feeders for continuous operation: when one feeder empties, another takes over.

    Double document detectors located at each feeder and the insertion area ensure no double documents are fed into the system. The 6406 Series utilizes electromechanical detectors which can operate with any print density, paper color, thickness or paper dust. Documents requiring inspection can be delivered automatically to the divert station. The 6406 Series also offers energy savings with its auto standby mode, which goes into effect after 1 hour of idle time.

    An optional CIS Scanner reads OMR, 1D and 2D Barcodes and OCR printed anywhere on the page, which provides the ability to automatically insert multiple-page documents, eliminating the tedious task of manually collating and inserting. Additional options include high-capacity production feeders, short feed trays for small inserts or BREs, side exit trays, custom cabinets and 402 Series Joggers.

    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 FD6406, 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 FD6406 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 $2560 for the base model, the 6404-Standard 2.


    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. Fair Market Value and Dollar Buyout leases are available, meaning you can buy the machine at the end of the lease for its fair market value or for $1 respectively. Approval can usually be done very quickly, normally over the phone. Please call for a quote.

    Click on the brochure and product video for more detail.

    Feed Hopper Capacity:
    Up to 325 sheets, 20# paper (each feeder)
    Envelope Hopper Capacity: •••Up to 325 envelopes, top-loading
    Vertical Output Stacker:Up to 500 filled envelopes, reverse stacking output
    Side Exit Tray (optional): •••
    Up to 500 filled envelopes
    Speed:Up to 4,000 pieces per hour, #10 envelopes
    Duty Cycle:Up to 60,000 pieces per month
    Paper Size:
    3.5" - 14"L x 5.1" - 9"W
    Envelope Size:
    6.3" - 9.7"W x 3.5" - 6.3"H
    Dimensions:65"L x 32"H x 16.5"D (four stations)
    Weight:Approx. 242 lbs.(four station)
    Voltage:100 Volts AC 50/60Hz
    Safety Certifications:
    UL, CE approved