a system for providing real - time , integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses , the system including at least one printing controller capable of receiving personalized printing data from at least one data source , the personalized printing data including envelope address information for a multiplicity of envelopes and personalized envelope contents information which varies for the multiplicity of envelopes and is matched to individual envelope addresses , the at least one printing controller being operative to merge and order the personalized printing data from the at least one data source such that it is printed in a desired distribution sorting order , selected to optimize postal savings in bulk mailings and at least one production facility for the individually addressed sealed envelopes containing personalized printed material matched to individual addresses , each of the at least one production facility including at least one digital printer operative to print the personalized printing data including the envelope address information for a plurality of envelopes to be formed from a substrate and the personalized envelope contents information for contents of the plurality of envelopes , at least one cutting stage receiving a printed output from the at least one digital printer and being operative to cut at least one of envelope sheets according to an envelope shaped blank and envelope contents sheets , at least one content - containing envelope formation stage operative to wrap the envelope sheets over the envelope contents sheets and thereby create sealed individually addressed envelopes containing personalized content matched thereto and a bundling stage , gathering and bundling the sealed individually addressed envelopes containing personalized contents matched thereto in the desired distribution sorting order .