Abstract: 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 l