Abstract: A method and apparatus for nest folding at least one smaller document of a collation while folding larger documents of the collation comprises the steps of: providing a buckle chute folder having a plurality of buckle chutes with one of the buckle chutes including a kicker structure adjacent a buckle chute stop; transporting to the buckle chute folder a collation having documents of at least two sizes; feeding the collation into the buckle chute having the kicker structure; buckling the larger of the documents into a nip of fold rollers as the lead edge of the collation hits the buckle chute stop; bouncing the smaller of the documents out of the buckle chute as the larger of the documents enter the nip of the fold rollers; and completing the first fold of the larger documents with the smaller documents nested within the first fold.

Abstract: A buckle chute folder for folding a plurality of paper sheets. The folder includes: a buckle chute; a pair of folding rollers downstream of the buckle chute; a curved paper guide downstream and adjacent the folding rollers for changing the direction of the folded sheets as they exit the folding rollers; and a pair of exit rollers downstream of the paper guide. One of the exit rollers has a fluorinated ethylene propylene sleeve whereby neither of the exit rollers feeds a paper sheet forming a part of the plurality of paper sheets ahead of any other of the paper sheets forming the plurality of paper sheets.