Apparatus for making a connected series of stuffed sealed envelope assemblies (conventionally referred to as "mailers") wherein a knife roll serves to control the advance of a return envelope toward a web providing an insert ply after which the knife severs the insert ply web along transverse terminal edges and without intermediate die cut connecting portions to provide the insert ply as fully useable segments (no waste) along with the series of return envelopes for envelopment between continuous webs to provide a series of mailers.
