Envelope Inserters / Invitation Mailing

We print a lot of invitations for mailing and are asked to insert the invitations into envelopes. Currently we do all this by hand but are considering purchasing an envelope inserter. We are told by vendors that the envelopes must be 1/2" larger than the piece(s) being inserted. The standard sized invitations (A6, A7, A8) are typically only 1/4" smaller than their companion envelopes. Does anybody have experience with this? Do the inserters really need that much clearance? Do you hope it will work or do you talk customers into smaller sizes? How much of your invitation mailings still have to be done by hand?
 
We do quite a bit of inserting by hand. I have had two different inseters and both would struggle without the 1/2 clearence, remember as the envelope opens the sides pull in so thicker inserts require more give on the sides. As far as invitations go, there is almost always another factor to keep them off the machines; Nesting of card inside, odd folds, belly bands blind match to inside envelope.
 

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