Abstract: A light sensor-containing apparatus for detecting the thickness of inserts placed within a mailer including a picker arm, movable picker jaw that pivots during an insert gripping process, a target plate having a light reflective surface and secured to the picker arm end that moves when gripping an insert, and a light sensor mounted to the picker arm that emits a light beam and receives a reflected light beam that is reflected back from the light reflective surface to establish the thickness of the insert as controlled by associated computer programming is presented.

Abstract: A system and method of sorting documents utilizing an algorithm or routine that alternates an order of documents with smallest sheet count documents followed by largest sheet count documents in order to optimizes a document throughput of an inserter based on a maximum speed that documents can be collated and accumulated and an algorithm or routine for optimizing the document throughput of a dual sheet cutter by grouping even sheet count documents together on evenly paired sheet boundaries within a mailing group of printed documents, with or without the use of dynamic motion control of the inserter.

Abstract: A paper roll cart for storing, holding for usage, and transporting a variably-sized roll of paper includes a wheeled base, a paper roll support that is rotationally mounted to the wheeled base, a paper roll securing mechanism coupled to the wheeled base for releasably anchoring the paper roll to the cart, and a cart movement control system attached to the wheeled base for assisting in the movement of the paper cart from one location to another location.

Abstract: A system and method of operation for proactively grouping disparate mail items that are queued to be produced in a processing facility, wherein the system and method utilize a manufacturing completion schedule for virtually grouping the mail items before physical production occurs and the system and method maximizes profitability by discounting the mail items by applying appropriate discount mailing regulations for virtually grouping the mail items before physical production occurs.

Abstract: A dynamic cue signal generator and method for processing one or more input and output signals to synchronize the operation of one or more associated machines and includes processes for creating a signal delay between receiving an input signal and issuing an output signal, for conditioning an input signal to produce an output signal with required parameters, for producing a plurality of outputs signals, for filling in undetected cues in an input signal to create a filled-in output signal, for filtering noise from an input signal to generate a noiseless output signal, and for generating an error output signal to indicate that an unusual event occurs in an input signal.

Abstract: A system and method of operation for proactively grouping disparate mail items that are queued to be produced in a processing facility, wherein the system and method utilize a manufacturing completion schedule for virtually grouping the mail items before physical production occurs and the system and method maximizes profitability by discounting the mail items by applying appropriate discount mailing regulations for virtually grouping the mail items before physical production occurs.

Abstract: A printed sheet handling system and method for use with lazy-portrait narrow-end to narrow-end (LPEE) formatted pages web printed pages to produce document sets includes: a printer to print LPEE formatted paired document pages on a continuous web; a slitter that divides the LPEE formatted printed web into two streams of sheets; collecting each stream in separate rolls of continuous sheets; withdrawing the stream of continuous sheets from a top of one roll, rotating the second roll 180°, and withdrawing the stream of continuous sheets from a bottom of the second roll; transferring each of the unwound streams of continuous sheets to a cutter that cuts each stream into individual pages; and collating the individual pages into correctly aligned and page number-sequenced document sets.

Abstract: For use with lazy-portrait narrow-end to narrow-end (LPEE) formatted document pages printed on a continuous web of material, a system and method for assembling correctly page-sequenced document sets that utilizes a slitter for separating the LPEE formatted document pages into two separate streams of continuous sheets, a turn-bar assembly positioned to flip only one of the continuous sheet streams, a cutter that produces separates pages from both the flipped stream of sheets and non-flipped stream of sheets, a collator for collating all of the separate pages into the correctly page-sequenced document sets, and a controller for tracking the LPEE formatted document pages and overseeing the assembly of the correctly page-sequenced document sets.

Abstract: A reduced-ink barcode is disclosed in which the barcode has printed dot foreground and non-printed background element regions assembled into a detectable pattern on a document and is printed with each of the printed dot foreground element regions having less than a maximum printed dot density.

Abstract: A system and method for printing documents on a continuous web of printable material by merging document data with form information and formatting the merged result into a printable simplexed or duplexed lazy-portrait narrow-edge-to-narrow-edge page format and printing the merged result to produce simplexed or duplexed lazy-portrait narrow-edge-to-narrow-edge pages on the continuous web of printable material.

Abstract: For use with lazy-portrait narrow-end to narrow-end (LPEE) formatted document pages printed on a continuous web of material, an apparatus and method of use for assembling correctly page-sequenced document sets that utilizes a slitter for separating the LPEE formatted document pages into two separate streams of continuous sheets that are loaded onto a document transfer cart that has two side-by-side and hinged-together document receiving trays, for each tray a removable bottom support plate assembly having casters on the lower portion of one of the bottom support plates, a top document delivery roller for each tray, a central hinge connecting the two trays to each another, support rack pivot rods, a handle secured to each tray, and cart transfer wheels.

Abstract: A system and method of sorting documents utilizing an algorithm or routine that alternates an order of documents with smallest sheet count documents followed by largest sheet count documents in order to optimizes a document throughput of an inserter based on a maximum speed that documents can be collated and accumulated and an algorithm or routine for optimizing the document throughput of a dual sheet cutter by grouping even sheet count documents together on evenly paired sheet boundaries within a mailing group of printed documents, with or without the use of dynamic motion control of the inserter.

Abstract: A printed sheet handling system and method for use with lazy-portrait narrow-end to narrow-end (LPEE) formatted pages web printed pages to produce document sets includes: a printer to print LPEE formatted paired document pages printed in 1 to N order and face up on a first half of the web and printed in N to 1 order and face down on a second half of the continuous web; a slitter that divides the LPEE formatted printed web into two streams of sheets, with one in 1 to N order and the other in N to 1 order; collecting both streams into separate stacks; flipping the N to 1 stack of sheets; and then withdrawing sheets from the tops of both stacks for cutting into pages, collating, and assembly into correctly aligned and page number-sequenced document sets.

Abstract: A web platform has multiple print modules adapted to print form data and variable data in a continuous operation. A controller with access to a form image database and a variable document database is connected to the web platform. Each print module on the web platform uses single color, ink jet, print heads. Form data is printed by a plurality of single color print modules. Variable data is printed by a single color print module. Bulk paper in rolls is fed through the web platform to print the forms and customer statements. The controller can direct printing of multiple statements simultaneously in discrete lanes on the web platform. Printed customer statements are subsequently separated into individual finished documents for process and mailing.

Abstract: A reduced-ink barcode is disclosed in which the barcode has printed dot foreground and non-printed background element regions assembled into a detectable pattern on a document and is printed with each of the printed dot foreground element regions having less than a maximum printed dot density.

Abstract: A printed sheet handling system and method for use with lazy-portrait narrow-end to narrow-end (LPEE) formatted pages web printed pages to produce document sets includes: a printer to print LPEE formatted paired document pages printed in 1 to N order and face up on a first half of the web and printed in N to 1 order and face down on a second half of the continuous web; a slitter that divides the LPEE formatted printed web into two streams of sheets, with one in 1 to N order and the other in N to 1 order; collecting both streams into separate stacks; flipping the N to 1 stack of sheets; and then withdrawing sheets from the tops of both stacks for cutting into pages, collating, and assembly into correctly aligned and page number-sequenced document sets.

Abstract: A system, apparatus, and method for printer-lane-packaging of documents utilizing a printer for printing on a linear web medium documents having fixed-data and variable-data information to produce in-lane formatting for each of the document and including a web cutter for cutting each of the in-lane printed documents into a stream of shingled sheets, a folder and collator for folding and collating the stream of shingled sheets into folded sets of variable page-counts per set for storage or immediate subsequent processing, and a computer for controlling the overall operation of the system components.

Abstract: A system and method are disclosed for a printing system that embeds tunneled messages into a data stream transferred along a data path. The embedded messages direct the operation of an associated system or device along the data path. The embedded messages are inserted No Operation or similar commands embedded by a preprocessor into the data stream and then emitted in a printing workcell for controlling the printer or associated system or device.

Abstract: A printed sheet handling system and method for use with lazy-portrait narrow-end to narrow-end (LPEE) formatted pages web printed pages to produce document sets includes: a printer to print LPEE formatted paired document pages on a continuous web; a slitter that divides the LPEE formatted printed web into two streams of sheets; collecting each stream in separate rolls of continuous sheets; withdrawing the stream of continuous sheets from a top of one roll, rotating the second roll 180°, and withdrawing the stream of continuous sheets from a bottom of the second roll; transferring each of the unwound streams of continuous sheets to a cutter that cuts each stream into individual pages; and collating the individual pages into correctly aligned and page number-sequenced document sets.

Abstract: For use with lazy-portrait narrow-end to narrow-end (LPEE) formatted document pages printed on a continuous web of material, an apparatus and method of use for assembling correctly page-sequenced document sets that utilizes a slitter for separating the LPEE formatted document pages into two separate streams of continuous sheets that are loaded onto a document transfer cart that has two side-by-side and hinged-together document receiving trays, for each tray a removable bottom support plate assembly having casters on the lower portion of one of the bottom support plates, a top document delivery roller for each tray, a central hinge connecting the two trays to each another, support rack pivot rods, a handle secured to each tray, and cart transfer wheels.