Patent ID: 6865864

Claim:
A method of making an inline package from a full repeat of a printed web, comprising: a) printing on a web a series of longitudinally extending repeats, each repeat having a length twice the length of a mailer, and a longitudinally extending outer wrap strip, the outer wrap strip including end to end rectangular front and back panels, the outer wrap strip including a rectangular front wrap panel and a rectangular back wrap panel located adjacent to and extending longitudinally along the longitudinally extending outer wrap strip; b) each repeat of the series of repeats including an insert section; c) the insert section including a first insert, a second insert located adjacent to and extending longitudinally along the longitudinally extending repeat, and a third insert located adjacent to and extending transversely relative to and away from the first insert; d) applying adhesive adjacent to the longitudinal edges of at least one of the front and back panels of the outer wrap strip; e) separating the outer wrap strip from the insert section of the web; f) forming the insert section into a plurality of strips of respective superposed lengths, each of which strips has a width slightly less than a lateral spacing between the adhesive applied to the outer wrap panels; g) forming a composite ribbon by bringing the outer wrap strip and the insert strips into superposed and registered position with each other; h) crossfolding a half of one repeat of the series of repeats of the composite ribbon back over another half of that one repeat, such that the front and back panels of the outer wrap strip fully enclose the folded insert repeat section; i) pressing the longitudinal edges of the folded front and back panels together and into sealed engagement with the adhesive to thereby close the outer wrap strip to form the closed outer wrapper; and j) transversely cutting the closed outer wrap strip off from the composite ribbon at a succeeding repeat.