Abstract: A processing system for automating the packaging, packing, unpacking, transfer/short term storage and loading of flats mail into flats sorters for sortation is disclosed. This involves bundling flats mail into bundles or logs and creating pallets for transporting in a standardized manner at mailer facilities such as publishers so that the sort depth and final destination of the bundle contents are preserved and used throughout its journey through postal facilities. Sort depth and destination bar coding is placed on each bundle. An automated method for palletizing involves creating a stack of bundles on a pallet in a predetermined sequence so that sorting processes in the postal facility become more efficient. Once the pallets are received at the postal facilities, the pallets are broken down in a pre-determined sequence in accordance with the sequence of original creation.

Abstract: A rejection rate of a selective sequential processing apparatus such as a mail sortation apparatus is reduced by combining results of at least two feature discrimination arrangements such as optical character recognition and a bar code reader based on comparisons of results of the feature discrimination results against each other and against expected values to validate at least one result and rejecting articles for manual processing only when no feature discrimination result can be validated. results of one feature discrimination technique can be used to augment results of another feature discrimination technique to improve selective processing accuracy and processing speed and throughput are increased by allowing use of faster or accelerated feature discrimination processes while maintaining a greater number of articles within the automated process.

Abstract: A flat mail sleeve packaging system which is adapted to stack product in a constrained homogenous mass. The system includes a first constraining wall and a second constraining wall. The second constraining wall is positioned with respect to the first constraining wall at a substantially perpendicular angle thereto. The first and second constraining walls are adapted for having the product placed therebetween with bound edges of the product all facing in a same direction without collapsing. A third constraining wall may also be provided forming a “U” shape with the first and second constraining walls.

Abstract: A flat mail edge biasing machine and method of use for separating stacks of bulk flats (products) into at least two separate stacks each with bound edges oriented in a same direction. The flat mail edge biasing machine has a feed head mechanism which is capable of detecting a bound or non-bound edge of the product, and sort the products based on the detection. The sorting includes moving the products from a center compartment to side compartments. In the side compartments, the products stacks with the bound edges oriented in a same direction.

Abstract: A mail handling system that imports data from a thickness measurement device regarding the thickness of a substantially flat mail article, counts the number of flat articles deposited on the top surface of the drop pocket, instructs the drop pocket to open to drop a unitary body of flat mail articles when the total stack thickness and/or number of articles exceeds threshold limits. A computer, operably connected to conventional conveyor system having, a drop pocket, a thickness measurement device, and a conveyor, implements the system.

Abstract: A system and method are provided for sorting a plurality of items into a predetermined sorted sequence. Items are initially located on initial sorting regions of a sorting apparatus. The items are then sorted into at least one intermediary sorted set and then sorted, from the intermediary sorted sets, into the final sorted sequence. A computer may be used to track the position of the items on the sorting apparatus and to control the movement of the items into the sorted sequence.

Abstract: A conveyor or article transportation system for conveying or transporting, for example, pieces or units of mail, or similar flat articles, has a pair of guide fingers operatively extending downstream from a downstream end of the conveyor so as to project into a stacking chamber within which the pieces or units of mail, or flat articles, are to be stacked. The guide fingers effectively vertically support the downstream end portions of the pieces or units of mail, or articles, such that the downstream end portions of the mail or articles do not curl or curve downwardly, or sag, whereby the pieces of mail or articles are deposited within the stacking chamber in a substantially flat state so as to prevent rollover of the pieces of mail or articles which would otherwise become jammed within the stacking system and cause upstream jamming or interruptions within the conveying system.

Abstract: A conveyor or article transportation system for conveying or transporting, for example, pieces or units of mail, or similar flat articles, has a pair of guide fingers operatively extending downstream from a downstream end of the conveyor so as to project into a stacking chamber within which the pieces or units of mail, or flat articles, are to be stacked. The guide fingers effectively vertically support the downstream end portions of the pieces or units of mail, or articles, such that the downstream end portions of the mail or articles do not curl or curve downwardly, or sag, whereby the pieces of mail or articles are deposited within the stacking chamber in a substantially flat state so as to prevent rollover of the pieces of mail or articles which would otherwise become jammed within the stacking system and cause upstream jamming or interruptions within the conveying system.

Abstract: A sortation process provides high-speed sorting of randomly ordered articles into a desired order in a plurality of ordered bins or tubs such as standard USPS tubs in two passes, without additionally marking the articles in any way or requiring additional processes to do so. Optical character recognition or bar code reading performed on an image of the article provides a sequence number which is used to place the articles in respective bins or tubs during a first pass. The process then presents the content of the bins or tubs in order for a second pass during which they are placed in final desired order among a final ordered group of bins or tubs. During the first pass, sequence number information can be collected and used for error checking against the order of articles in each bin or tub during a second pass. The final output of the process provides the articles in standard (e.g. USPS) tubs face up and in delivery order.